Cambi SolidStream - High Dry Solids Technology The Versatile Solution to Cake Reduction Pål Jahre Nilsen

Transcription

1 Because it matters Cambi SolidStream - High Dry Solids Technology The Versatile Solution to Cake Reduction Pål Jahre Nilsen 1

2 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

3 CAMBI WORLD WIDE MARKET SHARE THERMAL HYDROLYSIS >85% (Red bars are Cambi plants) 140,000 * = operating; **operating & expanded, (*) closed down (pilot/decommissioned), *? Uncertain operating status. All other under design/construction 120,000 Plant size [t DS/yr processed] 100,000 80,000 60,000 40,000 20,000 0

4 CAMBI SERVES A POPULATION OF MORE THAN 50 MILLION PEOPLE WORLD WIDE BEIJING LONDON WASHINGTON DC SINGAPORE SEOUL DUBLIN OSLO BRUSSELS ATHENS SANTIAGO DE CHILE EDINBURGH CARDIFF AND 20+ OTHER CITIES

5 CAMBI THERMAL HYDROLYSIS AT DCWATER, WASHINGTON DC 130,000 t DS/y, 4.3 mill. p.e. /390 MGD / 1350 MLD Greenhouse gas reduction: 28% -39% or 47,000 to 73,000 metric tons of CO 2 e (equivalent) per year, compared to traditional/today s solution CANCELLED traditional design New solution CAMBI THP Planned traditional design: + 8 egg-shaped digesters (8x4.5 MG*) + 4 batch silo digesters (4x2.5 MG*). Total volume: 46 MG =174,000 m 3 ) CANCELLED CAMBI Design Chosen: Cambi THP + 4 digesters, each of 3.8 MG* = 58,100 m 3 (1/3 of traditional volume) 35% overall CAPEX savings compared to traditional design OPEX savings = 20 mill. $/year from today s solution *MGD = Million gallons

6 OSLO FOOD WASTE BIOGAS & FERTILIZER PLANT, BY CAMBI

7 SUNDET, VÄXJÖ (SWEDEN) CO DIGESTION KEY FIGURES Design parametres THP type B6-2 Under start-up 8655 tds/year (to THP) 70% Biosolids 30% Biowaste Start up Oct 2014

8 WORLD SLUDGE PROUDCTION TRENDS, Cambi share of TDS Sewage Sludge generated 2015 Cambi 2015 Cambi 1000 metric tons DS/yr plant capacity market Country (1000 t DS/y) share United Kingdom 1,650 1,815 1, % Ireland % Norway % Baltics % Belgium % Finland % Chile % Netherlands % Denmark % Spain 1,150 1,265 2, % Sweden % Australasia , % United States 7,800 8,580 9, % Poland 700 1,050 1, % Germany 2,000 2,200 2, % Japan 2,330 2,563 2, % China 6,850 17,125 34, % Other West & South Europe 3,153 3,468 3, % India 4,770 9,540 23, % Middle East and Turkey 4,060 6,090 9, % Russia 2,610 3,915 4, % Brazil, Mexico, Colombia 2,020 4,040 8, % South Korea 890 1,068 1, % E-Europe & Balkans 888 1,776 1, % Total 43,801 68, ,069 1, % APAC: South Korea, Japan, Australasia (Singapore, Thailand, Burma, Vietnam, Indonesia, Malaysia, Philippines not yet mapped)

9 at a Glance: Global Market Adoption of Cambi THP 2015 Singapore 19 th Country adopts Cambi

10 CONVENTIONAL DIGESTION Gas engine Heat Biogas Electricity Raw sludge (5% DS) Digested sludge 3% DS Cake % DS Heat exchanger Anaerobic digestion

11 CAMBI THP & ADVANCED DIGESTION Gas engine (or turbine) Heat Biogas Electricity Raw sludge (16.5% DS) Hydrolysed sludge 12% DS Digested sludge 6% DS Cake >30% DS Class A Pressure cooker C / 30 min. - Reduces viscosity - Kills pathogens - Converts solids into easily digestable feed Anaerobic digestion

12 CAMBI THP Process The energy efficient and reliable steam explosion process Since 1996 process

13 Cambi Thermal Hydrolysis pre-treatment - WWTP Integration

14 Steam Explosion

15 Thermally hydrolysed. No Steam Explosion

16 Steam Exploded Hydrolysed Sludge

17 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

18 EFFICIENT DEWATERING Kapuciska, Poland 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

19 NAESTVED (DK, 2000) 8 MGD EXTENDED AERATION SLUDGE

20 EFFECT OF CAMBI ON MASS AND ENERGY BALANCE AT DUBLIN Conventional digestion Cambi THP digestion DS% feed 5% 12% Digester volume required 30,500m 3 12,750 m 3 VS destruction (15 days HRT) 42% 62% DS% cake 25% 34% Tonnes of cake 92,300 54,200 Tonnes Water Evaporation (t WE)/hour for drying (= MWs energy required in form of gas) Potential MW (electricity) generated from Biogas 11.2 t WE 5.7 t WE

21 CAMBI SLUDGE DISPOSAL Cambi cake is at the road fork of strategic planning of biosolids Low-quantity, pathogen free, no re-growth, stable, dry, low odourous product Digested cake Sludge disposal depending on cost and legislation Thermal processing Landfill Agriculture Reduced disposal cost for all disposal options Drying 1MWh/tWE Drying size 1/2 Incineration 2MWh/tWE Autothermic cake No further stabilisation required Class A product, Easy acceptance by farmer Less water to evaporate with Cambi sludge

22 Cambi THP Product range B 2 (2 m³ Reaktor) B 6 (6 m³ Reaktor) B 12 (12 m³ Reaktor) B3 (SolidStream) 2 reactor compact Compact Unit - Standardiced Unit -Pre-installed, factory tested and prepared for fast installation on site Middle size Projects - Standardiced Unit -Pre-fabricated and factory tested components -Assemby on site Large projects - Custom-made -Assemblyon site Solidstream Project -Standard Design -Pre-fabricated, preinstalled factory tested for fast installation and decommisioning on site 5 20 t DS/Day t DS/Day t DS/Day 20 t DS/Day/line

23 Standard Cambi THP Technology Steam CHP Electricity 850 kg/t DS Biogas Primary + Secondary sludge Sludgecake 17% DS 28 35% ds Pre-dewatering THP 9-12% DS Final dewatering Digestion (55 60% VSR) Reject water treatment Dilution water > 6 kg VS/m³/Day

24 Cambi THP Technology. WAS only Steam CHP Electricity 850 kg/t DS WAS Biogas WAS only Slude cake 17% DS 28 35% DS Pre-dewatering THP 6-9% DS Final dewatering Primary Sludge Bypass Digestion (55 60% VSR) 3 5 kg VS/m³/Day Reject treatment

25 Cambi I-THP Technology (i = intermediate) Electricity CHP Steam CHP Electricity Biogas 500 kg/t DS Biogas Thickened Sludge 5% DS Sludge cake 28 35% DS Per-dewatering THP Final dewatering Conventional digestion (40% VSR) Reject water treatment THP digestion (25 % VSR) Reject water treatment 1 2 kg VS./m³/Day 4-5 kg VS./m³/Day Dilution water THP digestion Total VSR 65%

26 Second Generation THP - Summary of performance by Thames Water Parameter Units Conv AD THP SAS only THP I-THP VSR % 44% 59% 55% 65% Gas Yield m3/tds Gas yield MWh/TDS 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 Support Fuel MWh/TDS Digester volume m3 46,350 14,300 26,250 29,000 THP Size % - 100% 40% 60% Dewaterability (min/max) %DS 21 \ \ \ \ 48? 26

27 Cambi SolidStream Concept Sludge Cake reduction 60%

28 The complete CambiSolidStream line for 20tDS/d

29 Lab Testing Thermal Hydrolysis and Steam Explosion Test Rig COD, SCOD, N, P, BMP Dewaterability

30 Energy recovery in centrate

31 Dewaterability tests in laboratory

32 Full scale continuous THP in Amperverband In operation from WAS only THP 21%DS -> 28%DS

33 SolidStream Pilot integration in existing building

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35 Process Scheme Base Case Amperverband 4000 tds/yr 60% Primary 79% VS 40% Secondary HRT = 28d To WWTP inlet 63% VS VSR = 55% DSR = 43% 21-23% DS t/yr Cake

36 Process Scheme SolidStream Full scale pilot in Amperverband +25% Biogas 4000 tds/yr 60% Primary 79% VS 40% Secondary HRT = 25d To WWTP inlet SolidStream 85-90% VS 55% VS VSR = 68% DSR = 53% 40-43% DS t/yr Cake

37 Dewatering and Cooling HighTemp centrifuge (70-100degC) Containerized 20 feet modules Cooling/Drying (Belt) Optional with waste heat 500kW Scrubber for odor control Dry solids in Amperverband: 39-41% DS from centrifuge 42-50% DS from Belt Cooler Granular No odors

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