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Integrated Gasification and NutrientRecovery from Waste Biomass
VETAANI Project Seminar, Helsinki09.04.2014
Ludwig Hermann, Stefan Krech
© Outotec – All rights reserved
Agenda
1. Introduction to Outotec2. Technology and expertise3. Motivation4. Resources & processes5. Challenges6. Product characteristics
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery2
89%of the order
intake,Environmental
Goods andServices, OECD
© Outotec – All rights reserved
Technology leader for over a century
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery3
Year
2013
2010
2006
2001
1990
1970
1950
1900
Listing on the Helsinki Stock Exchange
BOLIDEN CONTECH
OUTOKUMPU TECHNOLOGY
LURGIMETALLURGIE
OUTOKUMPU
NORDBERG GRINDING MILLS
KHD ALUMINIUMAISCO, SUPAFLO
WENMEC
LAROX
AUSMELT
ENERGYPRODUCTSOF IDAHO
SCANALYSEBACKFILL SPECIALISTS
TME Group, DEMIL MANUTENÇAONUMCORE
KILN SERVICES, VPFMILLTEAM, EDMESTON
AUBURN
ASH DEC
© Outotec – All rights reserved
Outotec by the numbers (2012)
• Sales EUR 2,087 million withEUR 476 million generated byservices
• 18 competence centers, presence in26 countries, deliveries to 80 countries
• Over 4,800 professionals• Extensive IPR portfolio
• Over 5,700 national patents/applications,630 patent families and 70 trademarks
• R&D expenditure EUR 42 million
• Market capitalization ~ EUR 2.0 bn• Listed on NASDAQ OMX Helsinki
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery4
Sales
366 426556
740
10001218
878970
1386
2087
0200400600800
1000120014001600180020002200
EUR million
Operating profit**
*) Combined basis, **) excl. One-time items and PPA amortizations
8 1124
52
96
120
5975
121
194
020406080
100120140160180200220
© Outotec – All rights reserved
Our long-term customers
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery5
Major global mining companies Intermediate sized companies
Selected reference customers of Outotec
© Outotec – All rights reserved
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery6
Technology & expertiseTechnology & expertise
© Outotec – All rights reserved
A snapshot of our benchmark technologies
• Half of the world's pyrometallurgicalprimary copper is produced withOutotec® Flash Smelting
• One-third of the world’shydrometallurgical copper isproduced with Outotec® SX-EW
• Over one-third of the world’s sulfuricacid capacity runs on Outotectechnology
• Most of the world's iron ore pelletsare produced using Outotec'straveling grate process
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery7
© Outotec – All rights reserved
Solutions for phosphate mining & processing
• Mining solutions• Beneficiation solutions including gravity
separation, flotation and comminution
• Sulfuric acid plants• World’s largest sulfuric acid plants have
been built by Outotec• Highest energy efficiency for steam and
electricity generation
• Calcination plants• Calcination with multiple energy recovery
stages for high impurity ores may includecadmium removal
• Services• Vanadium catalyst screening
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery8
© Outotec – All rights reserved
Fluidized bed based processes
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery9
Incineration - gasification
© Outotec – All rights reserved
Agenda
1. Introduction to Outotec2. Technology and expertise3. Motivation4. Resources & processes5. Challenges6. Product characteristic
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery10
2014 Outotec ranked3rd most sustainable
of all listed companies ofthe world!Corporate Knights,
World Economic Forum Davos 2014
© Outotec – All rights reserved
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery11
Source: Jensen, L.S., 2012
Manure + sludge = source of over-fertilization
© Outotec – All rights reserved
The key to over-fertilization is P-concentration!
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery12
If you have too much phosphorus-rich waste and not enoughcropland nearby – consider incineration!
=Concentration
• 1,5 t P2O5 1,5 t P2O5
Gasification
© Outotec – All rights reserved
Agenda
1. Introduction to Outotec2. Technology and expertise3. Motivation4. Resources & processes5. Challenges6. Product characteristic
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery13
© Outotec – All rights reserved
Manure140 Mt DM5 Mt P2O5
Sewage sludge12.5 Mt DM
750,000 t P2O5
Animal by-products cat. 1
1.5 Mt DM450,000 t P2O5
Plug-Flow
digestion
Biogas (SNG/LNG)
II.De-
watering
III.Drying
IV.Thermal
Conversion
V.Ash
processing
K + PKstruvite
SNG, steam,electricity
Secondaryresidues
Raw materialP(K)Fertilizer
ASH DECProcess
Process steps necessary to obtain ash as a phosphateconcentrate for transportation and further processing
7-8%DM
25-30%DM
45-95%DM
Renewable energy yield (technical potential) of EU28 manure:583 TWh (2,100,000 TJ) = 3-5% of total European energy supply
Relevant secondary P-flows in the EU28
Resources & recovery processes
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery14
NAmmonium-sulfate
Ash asRaw material
100%DM
© Outotec – All rights reserved
High efficiency drying – closed loop steam dryer
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery15
RTD Project DEBUGGER:Energy efficient steam dryer,
<400 kWh /t H2O
© Outotec – All rights reserved
Cattle manure to energy – Hereford (Tx)
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery16
The multi-fuel Outotec Energy Products system is designedto convert 420.000 tons of cattle manure a year into energyfor an ethanol plant.
© Outotec – All rights reserved
Sewage sludge to energy – State Zürich facility
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery17
Converts 100.000tonnes per year ofdewatered sludgefrom Zürich Stateto 7’000 MWh/yelectricity and35’500 MWh/y todistrict heating.
Designed and engineered for downstream phosphorus recovery!
93.9% of Zürich’s population votedin favor of new mono sewage sludgeincinerator in a referendum!
© Outotec – All rights reserved
Animal by-products to energy, High River (AB)Cargill MeatSolutions, HighRiver, Alberta,Canada
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery18
Conversion of 200‘000 tpy animal by-products to 400°C, 45bar superheated steam
© Outotec – All rights reserved
Double CFB steam gasification
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery19
GasificationT = 750 °C – 900 °C
RegenerationT = 850 °C – 950 °C
Ash
Ash
fuel
H2O (g)
(fuel)
air
silica sand(ash)
silica sandchar
H2O, H2, CO2,CO, CH4
(CxHy, Tar)
N2, CO2, O2,H2O (g)
(SO2, NOx)
© Outotec – All rights reserved
20 kWth dual fluidized bed facility, IFK Stuttgart University
- gasifier- bubbling bed reactor- diameter: 150-200 mm- height: 3 m
- regenerator- turbulent reactor- diameter: 70 mm- height: 12 m
- bed material: silica sand- gas analyses
- gasifierH2, CO, CH4 O2, CO2, CxHy
- regeneratorCO, O2, CO2, SO2, NOx
- electrical heating- volumetric fuel dosing
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery20
© Outotec – All rights reserved
First DFB steam gasification results (D. Schweitzer)
• DFB experiments at the 20 kWth test facility• with a maximal fuel particle size of < 2 mm, the occuring ash clusters had
no effect on the process• stable conditions for several hours were achieved
steam gasification of sewage sludge is possible
• First results indicate a promising behaviour• relatively high gas yield of 0.83 m³/kgfuel, daf• gas yield and energy output of sewage sludge slightly lower than for
wood
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery21
Fuel Tin °C
S/C ratioin molH2O/molC
Gas yieldin m³i.N.,dry/kgfuel, daf
Energy outputin MJ/kgfuel, daf
LHV syngasin MJ/m³i.N.,dry
Sewagesludge
775 1.57 0.83 10.8 13
Wood 760 1.74 0.95 12.2 12.8
Source Stuttgart University, IFK institute
© Outotec – All rights reserved
Biogas from biomass/RDF: Cemex Rüdersdorf
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery22
Design data:
Thermal capacity: 100MWFuels: Carbonic ashes, biomass, RDFProduct gas: 60000 Nm³/h, 3-5.3 MJ/Nm³, 860-920°CAsh: <1% carbon
Calciner
Rotary kiln burner
Source Cemex, Rüdersdorf
© Outotec – All rights reserved
Ash physical and chemical properties
•Ash is a mineral phosphate concentratewith more or less impurities & pollutants,depending on the feedstock!
•Like rock, ash is not afertilizer!
•Ash needs processing to becomebecome a fertilizer!
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery23
© Outotec – All rights reserved
Biomass ash vs. rock phosphate concentrate
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery24
1) Kley, G., 2004 2) http://www.biodat.eu/
Ash may beappropriate forreplacement of rockphosphate concentratein conventional BATfertilizer processes
© Outotec – All rights reserved
Biomass ash vs. rock phosphate concentrate
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery25
1) Kley, G., 2004 2) http://www.biodat.eu/
ASH DEC hasbeen speciallydesigned tocope withimpurities andpollutants!
© Outotec – All rights reserved
The ASH DEC Process
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery26
• Concentrating nutrients• Removing pollutants; HM = arsenic, cadmium, lead• Alkaline phosphate compounds available to crops
© Outotec – All rights reserved
Fließbild – Schlammverbrennung + ASH DEC
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery27
Process flow diagram100‘000 tonnes sewagesludge incineration
Sludge & manure incineration
© Outotec – All rights reserved
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery28
ASH DEC as an integrated part of biomass incineration
Ash from hot gas cyclonePre-heating of additives
Calcining in the rotary kilnMetal separation in hot gas filter
Flue gas cleaning in the SSI
© Outotec – All rights reserved
Various fertilizer options downstream
Example: production of NPKfertilizers from AN, SOP andtreated ash, scale 12 tph, atLonza AG; Visp, Switzerland
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery29
© Outotec – All rights reserved
Agenda
1. Introduction to Outotec2. Technology and expertise3. Motivation4. Resources & processes5. Challenges6. Product and ecological footprint
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery30
Source PSI, Villigen
© Outotec – All rights reserved
Build a closed-loop nutrient ecosystem
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery31
150.000 MWh/yearBiogas, Electricity &
Heat
1 Mt/yearmanure
30.000 tpyFertilizer
© Outotec – All rights reserved
Challenges
• Cooperation of/with livestock farmers to attain• Long-term, reliable supply of raw material
• Supply of >100’000 tonnes dewatered manure for one plant
• Effective nutrient separation and recovery in upstreamprocesses (N recovered as ammonium sulfate instead ofbeing lost during high temperature conversion)
• Efficient on-site use or subsidized sale of generated energy(biogas and/or electricity value > € 100/MWh)
• Foreseeable and favorable regulatory framework
• Comparatively high investments
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery32
© Outotec – All rights reserved
Agenda
1. Introduction to Outotec2. Technology and expertise3. Motivation4. Resources & processes5. Challenges6. Product and ecological footprint
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery33
© Outotec – All rights reserved
Corn pot test (M. Severin et al. 2014)
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery34
eff ef ef
d
bcd
abc
de
abcda
cdde
abc
def
abcd
ab
0
10
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30
40
50
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0-co
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TMEr
trag
[g]
Yield (DM)
Sandy soil 1,14 mg P/100g soil, pH 7,0 after neutralization with lime, Mitscherlich-pot 6 kg/pot, 9 corn cropsFertilizing in 3 steps (0,176; 0,352 and 0,528 g P per pot)
Dry
mat
tery
ield
(g)
© Outotec – All rights reserved
Corn pot test (M. Severin et al. 2014)
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery35
Sandy soil 1,14 mg P/100g soil, pH 7,0 after neutraiization with lime, Mitscherlich-pot 6 kg/pot, 9 corn cropsFertilizing in 3 steps (0,176; 0,352 and 0,528 g P per pot)
P-Aufnahme
gf g gf gf
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0,120-
cont
rol
USSA
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TMEr
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P-uptake
P-up
take
(gin
dry
mat
tery
ield
perp
ot)
© Outotec – All rights reserved
Energy footprint of fertilizer processes
7,14
22,72
16,78
5,25
61,16
55,46
0
10
20
30
40
50
60
70
Single superphosphate Acidulated sludge ash Calcined phosphate
GJ/
tP2O
5
Cumulated energy balance
Energy Consumption Energy Generation
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery36
© Outotec – All rights reserved
Comparative pollutant concentrations
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery37
© Outotec – All rights reserved
Tentative GaBi footprint for ASH DECCO2 from organic renewable resource neglected
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery38
GWP 0,65 kgCO2-Equiv.
© Outotec – All rights reserved
Conclusion
• Because of water quality concerns, continued buildup of soil P levels due to
land-applied manure and litter will not be a long-term option in most livestock
farming areas.
• Energy recovery (biogas, electricity and/or process steam) with ash export is a
promising high-volume alternative use for farmyard manure and poultry litter.
• Because of nutrient concentration and value in the ash, energy options provide
a built-in mechanism for economically exporting surplus P and associated
nutrients out of livestock farming areas.
• In fact, the economic viability of energy options depends on being able to
market ash for use in fertilizers outside concentrated livestock areas.
• No pathogens and odors in ash
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery39
© Outotec – All rights reserved
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery40
Thank you for your attention!
[email protected]@outotec.comwww.outotec.com Source: The Guardian
© Outotec – All rights reserved
Backup
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery41
© Outotec – All rights reserved
Executive summary
• Phosphate recycling is necessary for long term feed and food security• Farmyard manure and sewage sludge present a large potential for
energy and phosphate recovery
Outotec could provide a complete value chain solution for energy &phosphate recovery if• Drying efficiency can be significantly improved to generate net
revenues from energy conversion• Ash can be processed to phosphate fertilizers with profit by lowering
the production cost and increasing the product value• The supply and distribution chains can be closed by setting up
symbiotic co-operation between stakeholders• A supportive legal framework is enforced
Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery42