Giovanni Bergna, Marzio Sorlini Lariana Depur, TTS - LGCA

Evento Finale _Webinar 3 giugno 2021

A microbe-based value chain: TREatment and valorisation of texTILE wastewater

Studio di fattibilità e scale-up di processoGiovanni Bergna, Marzio Sorlini

Lariana Depur, TTS


Goals

1. Technology selection, sizing and operating conditions when scaling-up (PN/anammox, Algae, Fungi)

2. Definition of potential implementation scenarios and technical and economic performances

3. Identification of gaps to be bridged and improvement opportunities

4. Outline of a roadmap for project follow-up


Technology selection – PN/anammoxGeneral design data• Design flow rate: 40 m3d-1

• Operating flow rate: 10-40 m3d-1

• Influent concentration: 130-260 mgNtotL-1

• Target effluent concentration: < 50 mgNtotL-1

Scale-upFor the full-scale plant, a continuous-flow stirred tank reactor would be more suited than a sequencing batch reactor:• lower operating pressure and constant with

time• simpler process control and simpler operation

(constant concentration)• no need for gas tightness nor recirculation

circuit

• no need of a gas holding / balancing tank

• continuous discharge and no need of hydraulic level adjustment

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Choice #1: Microalgal speciesAccording to the main finalproduct (clean water and valuablebiomass), the growth of pureculture or the development ofmixed consortia are favoured.However, the cultivation of monospecies culture in open systemsfed on wastewater is very difficultdue to contamination, andeconomically not feasible

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Technology selection – Algae

Bagul, samadhan yuvraj et al., 2018). (a) Chlamydomonas sp.; (b) Chlorella sp.; (c) Scenedesmus sp.; (d) Chlorococcum sp.; (e) Westielopsis sp.; (f) Lyngbya sp.; (g) Nostoc sp.; (h) Phormidium sp.


Technology selection – AlgaeChoice #2: Cultivation system

The type of final products, the origin and composition of thewastewater, the capital and operation and maintenance costsare the driving forces behind this choice.Cultivation systems can be classified into open or closed. Theformer (ponds, lagoons, deep channels) are usually installedoutdoors, while the latter (flat panels, tubular reactors) areusually located indoor under artificial light or outdoors undersunlight and should include vessels of transparent materials.Recently, algal turf scrubber has been developed including anattached algal community (turf) growing on a shallow basinthrough (raceway) which water is constantly pumped in.

The dry matter of the algal biomass would range from 0.05–0.075% for open pond and up to 0.3–0.4% for closed systems.

The scale up design considers the implementation of a flatpanel photobioreactor (PBR) to maximize the penetration oflight, therefore biomass production and the microalgalnutrient uptake. Also, closed PBRs have a lower risk forcontamination and the metabolic pathways to enhancebioproduct accumulation in the biomass are easier to control

Green Wall Panel (GWP®-II) photobioreactors

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Technology selection – AlgaeChoice #3: Harvesting system

The function of harvesting anddewatering is to increase the totalsolid matter up to 10–25% of totaldry matter or even to a dry product.

Harvesting will be here carried outusing centrifugal separators with ahigh separation efficiency (>95%).Two centrifuges (12 m3 hour-1) havebeen selected for the task.

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Technology selection – AlgaeChoice #4: Exploitation of the algal biomass

Microalgae are renewable, sustainable, andeconomical sources of biofuels, bioactivemedicinal products, and food ingredients.Several microalgae species have beeninvestigated for their potential as value-addedproducts with remarkable pharmacologicaland biological qualities. As biofuels, they are aperfect substitute to liquid fossil fuels withrespect to cost, renewability, andenvironmental concerns. Microalgae have asignificant ability to convert atmosphericCO2 to useful products such as carbohydrates,lipids, and other bioactive metabolites.

Khan, M. I., et al. , 2018

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Implementation scenarios – synopsis


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DTP out PN/anammox out Microalgae out

Volume m3y-1 100.000,00 100.000,00 99.401,60

TSS mgL-1 100,00 100,00 60,00

COD mgL-1 600,00 420,00 294,00

BOD5 mgL-1 265,00 85,00 10,00

N mgL-1 250,00 70,00 17,50

P mgL-1 2,60 1,00 1,00

Implementation scenarios – water quality

Scenario 0 Scenario 1 Scenario 2


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Implementation scenarios – volumes in scenario 2

GWP-II flat panel

Algal paste

wastewater

High pressure homogenisation

Spray drying

High pressure extraction

PigmentsChlorophyllsCarotenoids

Extraction of added-value molecules

LipidsResidues

PN/anammox effluent

Storage tank

External company

Pigment = 4.8 kg day-1

Mass=159 Kg day-1

Biomass productivity = 178.12 Kg TSS day−1

(20% solids)

Pigment content= 3%Lipid content = 8 %

TSS = 9.4 Kg day-1

COD= 79.4 Kg day-1

TN= 5 Kg day-1

310.63 m3 day-1

Separationefficiency=95%

Biomass productivity = 187.5 Kg TSS day−1

(0. 12 % solids)= 40 tonne TSS ha

-1year

-1

COD removal efficiency=30%TN removal efficiency=75%

TP removal=100%(P is limited and must be dosed 2.7 Kg day

-1)

312.5 m3 day-1

COD= 131.3 Kg day-1

TN= 22 Kg day-1

TP=0.3 Kg day-1

Oil volume=14.3 L day-1


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Implementation scenarios – costs

PN/anammox Microalgae Extract CAS+tertiary TOT

Scenario 0 - € - € - € 236.820,0 € 236.820,0 €

Scenario 1 175.598,0 € - € - € 137.594,0 € 313.192,0 €

Scenario 2 175.598,0 € 499.499,4 € 61.555,1 € 87.055,0 € 823.707,5 €

57’000 Kg of algal biomass are produced in Scenario 2 and the process is expected to extract 1 Kg of pigment every 37.04 Kg of algal biomass. Thus about 1540 Kg of pigments are produced on a yearly basis. In order to balance the increased costs with respect to Scenario 1, each Kg of pigment has to be sold at 331,75 €/Kg. The price further increases if calculated with respect to Scenario 0: 381,37€/Kg.


Gaps and improvements3

• all assessments were carried out with reference to the legislation in force. Directive 91/271/EEC art.5 asks to ensure that the minimum percentageof reduction of the overall load entering all urban WWTP in a given area is at least 75% for total nitrogen produced; the same directive asks thatthe residual nitrogen concentration in WWTP discharges has to be maintained below 10 mg/l. To date these limits (especially the former) aresometimes derogated in textile (and other industrial) districts. If instead they were enforced, a PN/anammox treatment on DTP premises wouldbecome kind of mandatory. The early removal of pollutants is increasingly becoming an urgent necessity

• the PN/anammox process costs were estimated considering a scale-up of a demonstrator that is currently installed in SCR and referring to itsremoval performances. Further tests are recommended in order to reach more stable and reliable figures and to exploit economies of scale

• cultivation of other microalgal species, such as Chlorella sp and Arthrospira platensis, Porphyridium cruentum, Dunaliella salina, with high contentof valuable pigments (up to 14%), such as b-carotenoids, lutein, phycocyanin, should be considered

• the cultivation costs decrease with scale, thus wide areas and big water volumes should be considered to reduce the unitary processing costs.

• microalgae, including Scenedesmus sp., are able of synthetising high levels of lipids when cultivated under appropriate conditions. Nitrogenstarvation is often mentioned to favour lipid accumulation in the cell, however, it decreased drastically the growth rate. A strategy to increase thelipid content without affecting the microalgal growth could be to introduce a two-step procedure: in the first step, optimal growth conditions for ismaintained, then the culture conditions are changed to introduce sufficient stress (i.e. nutrient depletion) to induce over accumulation of lipids

• most of the cultivation cost derived from the centrifugation step. In an optimized design of the plant it is recommended to include a bulkharvesting step such as biomass dynamic thickener prior centrifugation to reduce the volume entering into the centrifugal separator, and relatedmachine and operating costs

• multiproduct chain facility should be considered for maximal exploitation of the microalgal biomass. A cascading process increases the biorefinerycosts significantly, but it should be compensated by the enhanced overall biomass revenue. Also, energy recovery as biodiesel and/or biogas fromthe residual biomass should be taken into consideration


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1 - Improve technical solutionsPN/anammox

Algae

Fungi

PN/anammox

Algae

Fungi

PN/anammox

Algae

Fungi

PN/anammox

Algae

Fungi

3 – Identify potential market and competitorsPN/anammox

Algae

Fungi

PN/anammox

Algae

Fungi

4 – Set-up the business model and analyse supply chains

PN/anammox

Algae

Fungi

PN/anammox

Algae

Fungi

PN/anammox

Algae

Fungi

PN/anammox

Algae

Fungi

PN/anammox

Algae

Fungi

2 – Address regulatory aspects / IP rights

1.3 Scale-up and engineering

1.2 Demonstration

1.1 - R&D activities & lab tests

7 – Go to the market

6 – Identify scale-up financing sources

5 – Develop business plans

4.2 Supply chain analysis and roles

4.1 Business Model identification

3.2 Investigation on competitors and alternative techs

3.1 Identification of target markets and customers


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Roadmap and opportunitiesCall title Description Details PN/anammox Microalgae Fungi

HORIZON-CL4-2021-TWIN-

TRANSITION-01-14

Deploying industrial-urban symbiosis

demonstrators for the utilisation of energy,

water, industrial waste and byproducts at

regional scale

"Activities are expected to start at TRL 4 and achieve TRL 6 by the end of the project"

"Reduce by 50% (in weight or volume) industrial waste generation and reduce significantly the associated GHG

emissions, by re-using and transforming waste, byproducts and side-streams into new resources or raw materials"

na +++ ++

C5-D2-BT-05-2021 Technologies for non-CO2 greenhouse gases

removal

"Develop technologies for addressing the effects of non-CO2 greenhouse gas emissions."

"Investigate techno-economic aspects of technologies and physical properties of emissions striving to match both

into market-ready solutions"

"Development of technologies for removing non-CO2 greenhouse gases CH4, N2O and fluorinated gases."

++ = =

HORIZON-CL6-2021-CircBio-

01-08

Unlocking the potential of algae potential for

a thriving European blue bioeconomy

"Activities are expected to achieve TRL 7 by the end of the project"

"The successful proposal will support the development of algae-based greener aquatic industrial

products/processes and/or environmental services"

na +++ na

HORIZON-CL6-2021-

ZEROPOLLUTION-01-01

Regional nitrogen and phosphorus load

reduction approach within safe ecological

boundaries

"Coordination and Support Actions"

"systemic approach preventing pollution from nitrogen and phosphorus, in line with the Zero Pollution Ambition."

"Best practices shared in EU and Associated Countries to prevent pollution from nitrogen and phosphorus

emissions to air/soil/water including the design of inter-sectorial governance models and policy implementation

tools"

++ na na

HORIZON-CL6-2021-

ZEROPOLLUTION-01-03

Preventing and managing diffuse pollution in

urban water runoff

"achieve TRL 5"

"prevent pollution of freshwater and soils"

"Implement advanced preventive and mitigating strategies to reduce diffuse pollution of urban waters "

+ ++ ++

HORIZON-CL6-2021-

ZEROPOLLUTION-01-06

Increasing the environmental performance

of industrial processes in bio-based sectors:

construction, woodworking, textiles, pulp

and paper and bio-chemicals

"achieve TRL 5"

"Improvement of the environmental performance of industrial processes in the following bio-based sectors:

construction, woodworking, textiles, pulp and paper, and bio- chemicals"

"Identify and evaluate possible solutions to improve the environmental performance of bio-based processes"

+ +++ +

LIFE - Circular economy and

quality of lifeTopics still missing na +++ +

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Marzio Sorlini

[email protected]

Progetto finanziato da:

Partners:

mailto:[email protected]

Giovanni Bergna, Marzio Sorlini Lariana Depur, TTS - LGCA

Documents

Transcript of Giovanni Bergna, Marzio Sorlini Lariana Depur, TTS - LGCA