Cambi Thermal Hydrolysis
From Waste to Worth
Polish Cities to Norway 14.09, 2016,
Lindum, Drammen
CAMBI is...
...Leading provider of technology for the conversion of sludge to renewable
energy and high-quality bio solids.
…World-leading in thermal hydrolysis and committed to quality in deliveries,
competence and expertise:
Since 1995 we have built 40 plants and have 16 plants under construction, in 21
countries
Total capacity to treat sludge and food waste from >53 mill. people, 1.55 million tons
DS/year.
…Disruptive and part of “Water Revolution”
The group had an outstanding performance in 2015 with several new
contracts and a solid order backlog.
CAMBI PLANT LOCATIONS
CAMBI SERVES A POPULATION OF MORE THAN
50 MILLION PEOPLE WORLD WIDE
SEOUL – DUBLIN – OSLO – BRUSSELS – ATHENS
SANTIAGO DE CHILE – EDINBURGH – CARDIFF – AND 20+ OTHER CITIES
BEIJING
LONDON
WASHINGTON DC
SINGAPORE
HAMAR
Aten
OURENSE BURNLEY
DRAMMEN STAVANGER
NÆSTVED
BYDGOSSZCZ
FREDRICIA
CAMBI PLANTS: 20 years full scale experience,
Delivered capacity range: 1,600 – 149,000 TDS/year, MEDIUM CITIES
CambiTHP® IN UK
CambiTHP®
treats >30% of
UK’s sewage
sludge.
Minworth STW, Birmingham (2016), Cambi 3 x B6-4, Severn Trent Water
• 2.5 million people
• Better dewatering >30% DS – 22% DS today
• cake quantity will be greatly reduced
• Class A product gives them more security
• shut down their incinerator
• Lee odorous cake product
• Improved biogas yields
• More import capacity including glycerol – so
more biogas
• Integrated with Gas to Grid
Basingstoke (2016), Cambi 1 x B6-4, Thames Water
DAVYHULME, Cambi in a WWTP
CambiTHP®, “Turbo-charging” Biogas Plants for Sewage Sludge
(CAMBI XXL: DAVYHULME, UK, 91,000 t DS/year (1000 MLD)
Please
don’t
boil me
I’m feeling
the
pressure CambiTHP®
B12-4x5 reactors
8 x 7500 m3
digesters
MEDIUM; KAPUSCISKA WWTP, BYDGOSZCZ, POLAND
8000 t DS/y
Lindum, Sludge Centre
ADVANTAGES OF CAMBI THERMAL HYDROLYSIS
VS CONVENTIONAL ANAEROBIC DIGESTION
Cambi Thermal Hydrolysis pre-treatment - WWTP Integration
CAMBI THP – EFFECTS FROM PRESSURE COOKING SLUDGE
Dewatered
15% DS
Hydrolysed sludge
12-13% DS
Mix of digested
sludge and
hydrolysed sludge
to digester
7-8% DS
Digested sludge
6 %DS Dewatered cake
30-35% DS
NAESTVED (DK, 2000) – 8 MGD EXTENDED AERATION SLUDGE
Before CAMBI:
20,000 tpy, 20-22% DS,
Smelly, high level of pathogens
After :
10,000 tpy Cambi cake
30-33% DS
Low odour
Free of pathogens
EFFICIENT DEWATERING – Kapuciska, Poland
CAMBI SIGNIFICANTLY REDUCES CARBON FOOTPRINT
Oslo EGE: 10,000 t
CO2e/year
DCWATER/Blue
Plains:
From 47,000 - 73,000 t
CO2e/year
Davyhulme:
32,000 t CO2e/year
Bran Sands:
50,000 t CO2e/year
Cardiff + Afan:
37,000 t CO2e/year
“… [The] thermal
hydrolysis pretreatment
system at …
Davyhulme … will
reduce [United
Utilities’] carbon
footprint by 8% - the
equivalent of removing
270,000 cars off the
road for 30 years.”,
March-April 2009,
Worldwater
CAMBI EFFECT: END-PRODUCT QUALITY – ABERDEEN
16,5000 tons DS/year
Conventionally treated sludges :
99% pathogen removal
Enhanced treated sludges :
99,9999% pathogen removal
SAFE RECYCLING OF BIOSOLIDS TO FARMLAND (UK)
Cambi cake is at the crossroads of strategic planning of biosolids
Capital expenditure and operating costs directly linked
to cost of tonne of water evaporation (tWE)/disposal
Drying makes no sense for agriculture at most transport
costs –only if agriculture option is not available
Digested cake to agriculture based on stackable safe, non smelly , low volume product –
it’s a transport business
Digested cake
No agriculture
Landfill – normally much more
expensive than agriculture
Drying
1MWh/tWE
Drying size 1/2
Incineration
2MWh/tWE
Autothermic cake
agriculture
Lowest cost option
Cost/t transport and sales income
Less/no water to evaporate
with Cambi treatment
Less Biosolids Transport/disposal
with Cambi treatment
the future for sludge treatment:
WATER IS THE MAJOR COST OF SLUDGE DISPOSAL
THP
Cambi standardized models, B2, B6 and B12
LARGE PLANTS: BRAN SANDS, UK 40,000 tons DS/year
Cambi THP
B12-2x4 reactors
3 x 6300 m3
digesters
CAMBI THP AT BLUE PLAINS WWTP (390 MGD, 1400 MLD, 4
MILLION P.E.) WASHINGTON DC, 400 DRY TONS PER DAY.
174,000m3 designed originally 4 digesters, = 58,100 m3 (1/3 of traditional)
Saved $200 million CAPEX vs traditional
Saved >$20 mill in OPEX/year
PLANNED TRADITIONAL DESIGN CAMBI SOLUTION
NEW SOLUTION
CANCELLED TRADITIONAL DESIGN CAMBI PROCESS
RESOURCE RECOVERY AT BLUE PLAINS WWTP, WASHINGTON
DC
XIAOHONGMEN & GAOBEIDIAN FIRST 2 OF 5 CAMBI THP PROJECTS IN BEIJING
We need Compact & standardized solutions to cut
integration and engineering costs
Cambi B2 THP: Leigh (UU), UK, workshop + Installation
LEIGH
• Up to 20 metric tons DS/day
• 1 x 3,300 m³ digesters
• ~10% DS feed to digesters
• 2 x 527 kW + steam
• B2-4 reactor Cambi THP
• Cambi cake to agriculture
Cambi with drying: Psyttalia, Athens – 5 mill. p.e. plant, 720,000 m3/d
CambiTHP, treating all WAS from one
digestion line of 4 x 10,000 m³ digesters
Hydrolyzed sludge mixed with raw primary
prior to AD: 15,500 metric tonnes DS/year, 43
t DS/day
20% overall WWTP energy savings
15-20% expected increase in biogas
production.
Final product >28% DS, from current 22% DS
35% reduction in drying requirement
Financed on operating savings
BIOWASTE REFERENCES
Lillehammer plant 2001, cap. 14 000 t/a
Outputs: El/CHP, bio-fertilizer to farmers
Ecopro plant, 2008, cap. 30-40 000 t/a
Outputs: El/CHP, bio-fertilizer to farmers
Oslo biogas plant, 2012, cap. 50 000 t/a
Outputs: Upgraded biogas to vehicle fuel gas,
bio-fertilizer to farmers
ECOPRO, NORWAY
Processes organic waste and sludge
from 51 municipalities in mid-Norway
Started up March 2008
Cambi construction contract +
operations
Satisfies EU animal by-product
regulation
THE OSLO FOOD WASTE BIOGAS & FERTILIZER PLANT, BY CAMBI
AN YANG – CO DIGESTION PLANT SOUTH KOREA
THP type B12-4
Under construction
Design parametres
– 28 000 tDS/year
– 65% Biosolids
– 35% Biowaste
Start up 2016
Cambi THP
Full scale continuous THP in Amperverband In operation from 2009-2015
WAS only THP
21%DS -> 28%DS
Hydrolysate (soluble COD)
to digester
Sludge cake
40-60% DS
Steam
Biogas
+ 20-30%
SOLIDSTREAMTM IMPROVED DEWATERING AND BIOGAS PRODUCTION
CAMBI SOLIDSTREAM, SLUDGE CAKE REDUCTION
PROCESS SCHEME SolidStreamTM
AMPERVERBAND GERMANY 2015
60% Primary
40% Secondary
79% VS
To WWTP inlet
VSR = 68%
DSR = 53%
40-43% DS
4 000 t/yr Cake
HRT = 25d
4000 tDS/yr
Solid
Str
eam
55% VS
85-90% VS
+25% BIOGAS
60% LESS CAKE
Cambi SolidStream Cake
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
Pla
nt
size
[t
DS
/yr
pro
cess
ed
]
* = operating; **operating & expanded, (*) closed down (pilot/decommissioned), *? Uncertain operating status. All other under design/construction
CAMBI WORLDWIDE MARKET SHARE, THERMAL HYDROLYSIS >
85%
* = operating; **operating & expanded, (*) closed down (pilot/decommissioned), *? Uncertain operating status. All other under
design/construction
Cambi THP
Biothelys, Veolia
Exelys, Veolia
Lysotherm, Eliquo Water
TurboTec, Sustec
Chinese suppliers (4)
Haarslev
METRIC
Market share, by capacity (t DS/y)
Plant ex-
pansions
Cambi 1,576,360 86.6 % 53 71% 31 79% 4
Biothelys 72,400 4.0 % 7 9% 6 15% 0
Exelys 48,200 2.6 % 5 7% 2 5% 0
Lysotherm 10,000 0.5 % 2 3% 1 3% 0
Sustec 16,000 0.9 % 2 3% 1 3% 0
Haarslev 5,200 0.3 % 1 1% 1 3% 0
Chinese 91,250 5.0 % 5 7% 5 13% 0
TOTAL 1,819,410 100.0 % 75 100% 39 100% 4
Finished/Oper-ating,
By number
Total Plants, By
number
Cambi
Other
suppliers
Top 4 Reasons for Cambi
• Reduced Capital Cost • Cambi is less expensive than new
digesters
• Cambi likely less expensive than digester
refurbishment
• Reduced Operating Cost • Dramatic decrease in biosolids leaving
the plant + Class A
• Integrates well with on-site power and
use of heat from engines
• Reduces GHG emissions • DC Water 40% reduction in GHG
• Provides Security for Solids
Handling and Cost (Reduces
Risk) • Known and predictable capital and
operating cost
• Reduced volume of solids
• Class A product allows for more options
• Eliminates the risk of rapid (e-coli)
regrowth and odors
Power from the People – with CAMBI THANKS FOR YOUR ATTENTION! QUESTIONS?
BACK UP
Program Benefits with CambiTHP
advanced digestion at DC Water
Reduce biosolids quantities by more than 50%
Improve product quality (Class A and more)
Generate 13 MW (net 10 MW) of clean,
renewable power from the CHP
Cut GHG emissions by ~57,000 tonnes/yr
Save millions of dollars annually when the
facility begins operating in 2014
Reinventing Biosolids
41
Cake Blending and
Dilution
Thermal Hydrolysis
Digestion Digested Sludge
CHP Plant
Cake Reception
Electricity to
ASD and
RSTC Plant
Excess Electricity
Exported to ETW
Biogas
RSTC
Phase 1
RSTC
Phase 2
CAMBI INTEGRATION, LARGE SCALE (BRAN SANDS, TEES
VALLEY, ENGLAND)
Drivers impacting sludge treatment
Phosphorous Energy
Sustainability Fertilisers
CAMBI ORGANIZATION
Founded in Norway in 1989, Cambi has today more
than 125 employees and representatives, local
offices in 9 countries.
Cambi’s headquarter is in Asker, (Oslo), Norway.
Cambi’s manufacturing site is in, Congleton,
(Manchester),UK
PRINCIPLES OF CAMBI HYDROLYSIS
Batch heat sterilization
Meets all known safety standards worldwide, USEPA alternate 1 time/temp Class A batch – no reactivation
Destruction of Extra Cellular Polymer – ECP
Sludge becomes compressible for dewatering (10% DS% gain) and less viscous (10% hydrolysed =~ 5% conventional)
Hydrolysis of insoluble COD
30-50% solubilisation enables very rapid digestion, 10 days HRT, 60% VSR
Steam disintegration of particulate matter
Increases digestion rate and reduces viscosity further
THE CAMBI VALUE PROPOSITION FOR MUNICIPAL SLUDGE AND ORGANIC WASTE
Reduce or eliminate residual
waste disposal. Recover nutrients and
produce Class A Fertilizer.
Generate clean,
renewable energy from
waste.
Cut greenhouse emissions
dramatically.
Save millions in annual costs for the
cities.
THE GREAT CITIES OF THE PRESENT WERE
BUILT AROUND NATURAL RESOURCES
THE GREAT CITIES OF THE FUTURE ARE
BUILT AROUND HUMAN RESOURCES
H U M A N R E S O U R C E S D E M A N D
C L E A N C I T I E S
For a City to remain great, it
needs to attract Human
Resources.
As cities attract more and
more people, a strategy is
needed for dealing with
Human Waste.
The sewer is the conscience
of the city
PEOPLE DEMAND CLEAN
WATER, AIR, AND CITIES.
THE CHALLENGE IS THAT PEOPLE GENERATE WASTE AND
REQUIRE INCREASING AMOUNTS OF WATER AND ENERGY.
THE CAMBI SOLUTION TURNS
PROBLEMS INTO PRODUCTS:
FROM WASTE TO WORTH
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
United Kingdom& Ireland
United States Europe West andMiddle East
Scandinavia andEurope Central
Iberia/LatinAmerica
China India Russia, Baltics, E-Europe & Balkans
S-Korea, Japan,Australasia
2010, 2020, 2030
Cambi Analysis: WORLD SLUDGE PROUDCTION TRENDS M
illio
n tons d
ry s
olid
s/y
ear
APAC: South Korea, Japan, Australasia (Singapore, Thailand, Burma, Vietnam, Indonesia, Malaysia, Philippines
not yet mapped)
Odour
Biogas
Carbon
Footprint
Critical Decision Making Criterias For Biogas Plants
Product
Quality
Disposal
Costs O&M
Costs
Digester
Volume
Plant
Footprint
Plant
payback
Odour
Cambi THP Positively
Impacts all of them
Cambi THP plant range
2 reactor compact
B – 2 (2 m³ reactor) B – 6 (6 m³ reactor) B – 12 (12 m³ reactor)
Small size projects
- Standardised package unit
- pre-assembled & pre-tested
- containerized unit
Medium-large size projects
- Standardised package unit
- Pre-assembled skids
Extra large size projects
- custom-made
- on-site construction
5 – 20 tDS/day 20 – 80 tDS/day 60 – 500 tDS/day
Second Generation THP - Summary of performance by Thames
Water
55
Parameter Units Conv AD THP SAS only
THP
I-THP
VSR % 44% 59% 55% 65%
Gas Yield m3/TDS 339 454 421 503
Gas yield MWh/TDS 2.16 2.90 2.69 3.21
Elec Efficiency (gross) % 15.3% 20.6% 19.1% 22.8%
Elec Efficiency (net) % 12.3% 14.4% 12.9% 16.6%
Electrical Output MWh/TDS 0.72 0.97 0.90 1.07
Support Fuel MWh/TDS - 0.28 - -
Digester volume m3 46,350 14,300 26,250 29,000
THP Size % - 100% 40% 60% Dewaterability
(min/max) %DS 21 \ 30 32 \ 45 28 \ 35 34 \ 48?
Cambi Converts Sludge to Dry and Compost-like Class-A
Product
Reduce volume to land Increase value recovery
Dewatered cake after Cambi
THP at Thames Water
Agriculture is the backbone of the DCWATER biosolids
program – 90% of material is land applied
57
DC Water and Sewer Authority Biosolids
Reuse Program
WITH BIOSOLIDS: -Drought resistance
-N+P and micronutrients
WITHOUT
BIOSOLIDS
(chemical fertilizer)