Because it matters Cambi SolidStream - High Dry Solids Technology The Versatile Solution to Cake Reduction Pål Jahre Nilsen 1
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
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
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
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
OSLO FOOD WASTE BIOGAS & FERTILIZER PLANT, BY CAMBI
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
WORLD SLUDGE PROUDCTION TRENDS, Cambi share of TDS Sewage Sludge generated 2015 Cambi 2015 Cambi 1000 metric tons DS/yr plant capacity market Country 2010 2020 2030 (1000 t DS/y) share United Kingdom 1,650 1,815 1,997 463 28.0 % Ireland 240 252 265 56 23.3 % Norway 120 132 145 22 17.9 % Baltics 190 228 274 23 12.1 % Belgium 200 240 264 20 10.0 % Finland 150 180 198 14 9.3 % Chile 310 465 558 25 8.1 % Netherlands 550 660 726 40 7.3 % Denmark 150 165 182 10 6.4 % Spain 1,150 1,265 2,657 43 3.7 % Sweden 250 275 303 4 1.7 % Australasia 770 924 1,109 13 1.7 % United States 7,800 8,580 9,438 157 2.0 % Poland 700 1,050 1,155 8 1.1 % Germany 2,000 2,200 2,310 2 0.1 % Japan 2,330 2,563 2,819 1.2 0.1 % China 6,850 17,125 34,250 447.4 6.5 % Other West & South Europe 3,153 3,468 3,815 15.5 0.5 % India 4,770 9,540 23,850 0.0 0.0 % Middle East and Turkey 4,060 6,090 9,135 0.0 0.0 % Russia 2,610 3,915 4,307 0.0 0.0 % Brazil, Mexico, Colombia 2,020 4,040 8,080 0.0 0.0 % South Korea 890 1,068 1,282 27.7 3.1 % E-Europe & Balkans 888 1,776 1,954 0.0 0.0 % Total 43,801 68,016 111,069 1,391.3 3.2 % APAC: South Korea, Japan, Australasia (Singapore, Thailand, Burma, Vietnam, Indonesia, Malaysia, Philippines not yet mapped)
2010-2015 at a Glance: Global Market Adoption of Cambi THP 2015 Singapore 19 th Country adopts Cambi
CONVENTIONAL DIGESTION Gas engine Heat Biogas Electricity Raw sludge (5% DS) Digested sludge 3% DS Cake 20 25 % DS Heat exchanger Anaerobic digestion
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 - 165 C / 30 min. - Reduces viscosity - Kills pathogens - Converts solids into easily digestable feed Anaerobic digestion
CAMBI THP Process The energy efficient and reliable steam explosion process Since 1996 process
Cambi Thermal Hydrolysis pre-treatment - WWTP Integration
Steam Explosion
Thermally hydrolysed. No Steam Explosion
Steam Exploded Hydrolysed Sludge
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
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
NAESTVED (DK, 2000) 8 MGD EXTENDED AERATION SLUDGE
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 2.9 4.0
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
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 20 80 t DS/Day 60 500 t DS/Day 20 t DS/Day/line
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
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
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%
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 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? 26
Cambi SolidStream Concept Sludge Cake reduction 60%
The complete CambiSolidStream line for 20tDS/d
Lab Testing Thermal Hydrolysis and Steam Explosion Test Rig COD, SCOD, N, P, BMP Dewaterability
Energy recovery in centrate
Dewaterability tests in laboratory
Full scale continuous THP in Amperverband In operation from 2009-2015 WAS only THP 21%DS -> 28%DS
SolidStream Pilot integration in existing building
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 10 000 t/yr Cake
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 4 000 t/yr Cake
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