PRC PDA: Sludge Beneficial Uses (Final Report)

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W ATER FINANCING P ARTNERSHIP F ACILITY PILOT AND DEMONSTRATION ACTIVITY

PRC-PILOT STUDY ON BENEFICIAL USE OF SLUDGE

FINAL REPORT

PREPARED FOR

THE ASIAN DEVELOPMENT B ANK M ANILA, PHILIPPINES

BY

WUHAN URBAN DRAINAGE DEVELOPMENT CO., LTD

WUHAN, HUBEI, PRC30 JUNE 2009

The views expressed in this paper/presentation are the views of the author and do not necessarilyreflect the views or policies of the Asian Development Bank (ADB), or its Board of Governors, or thegovernments they represent. ADB does not guarantee the accuracy of the data included in this paper

and accepts no responsibility for any consequence of their use. Terminology used may not necessarilybe consistent with ADB official terms.



Wuhan Urban Drainage Development Co. Ltd. PDA: Beneficial Use of Sludge

i Final Report, 30 June 2009

TABLE OF CONTENTS

SECTION 1 INTRODUCTION ............................................................................................ 1

1.1 Project Background ................................................................................................ 1

1.2 Objectives and Scope of the PDA .......................................................................... 2 1.3 Implementation Schedule ....................................................................................... 2

SECTION 2 METHODOLOGY AND PILOT STUDY ACHIEVEMENT............................ 4

2.1 Technical Principle for the Study ............................................................................ 4

2.2 The Conclusion of Bench-Scale Study ................................................................... 4

2.3 General Physical Progress ..................................................................................... 4

2.3.1 Sites Selection for Pilot Study ..................................................................... 5

2.3.2 Pilot Study Facility System Design.............................................................. 6

2.3.3 Pilot Study Facility Installation/Construction................................................ 9

2.3.4 Protein Extraction ...................................................................................... 10

2.3.5 Laboratory Analysis of Protein and Hydrolysis Residue............................ 12

2.3.6 Sludge Hydrolysis Residue Gardening Application ................................... 14

2.3.7 Gardening Record ..................................................................................... 16 2.3.8 End-Users Survey ..................................................................................... 17

2.3.9 Financial Viability Study............................................................................. 17

2.4 Issues Identified During Pilot Study...................................................................... 18

SECTION 3 PROJECT MANAGEMENT.......................................................................... 19

3.1 Project Management Structure............................................................................. 19

3.1.1 Background ............................................................................................... 19

3.1.2 Responsibilities.......................................................................................... 19

3.1.3 Tasks Undertaken ..................................................................................... 20

3.2 Reporting .............................................................................................................. 20

3.3 WFPF Funds Utilization........................................................................................ 20

3.3.1 Contract Awards and Expenditure............................................................. 21

3.3.2 Disbursement ............................................................................................ 21

SECTION 4 OUTPUTS AND OUTCOMES ...................................................................... 23

4.1 Outputs ................................................................................................................. 23

4.2 Outcomes ............................................................................................................. 23

4.3 Impacts ................................................................................................................. 23

4.4 Further Actions ..................................................................................................... 23

4.4.1 Follow-Up of Pilot Study Achievement ...................................................... 23

4.4.2 Further Pilot Study on Protein Liquid Industrial Application....................... 23

APPENDIX A UPDATED IMPLEMENTATION SCHEDULE .............................................. 25

APPENDIX B Staf fing Schedule .................................................................................... 26

APPENDIX C1 END-USER QUESTIONNAIRE................................................................ 27

APPENDIX C2 FEEDBACK OF END-USER QUESTIONNAIRE ....................................... 28 APPENDIX D STATEMENT OF EXPENDITURES............................................................. 29




1 Final Report, 30 June 2009

SECTION 1 INTRODUCTION

1.1 Project Background

ADB is currently supporting serials of Wuhan wastewater management project, including ADB Financed Phase I (Loan No.1996-PRC): wastewater management, capacityconstruction and water quality modeling; ADB Financed Phase II (Loan No.2240-PRC): stormwater management, wastewater management, capacity construction and sludgemanagement. Also, Wuhan is currently preparing a new project for the solid waste and sludgemanagement (ADB Financed Phase III).

There are 10 wastewater treatment plants (6 of which are financed by ADB) in operation withtotal capacity of 1.59 million tons a day (1.0 million ton/day by ADB Projects), andapproximately 500~600 tons of sludge (water content is 80%) is produced every day. Atpresent, the sludge is transported and disposed at the landfill plants. According to theMunicipal Urban Development General Plan, the landfills in the suburban area would beshutdown in the next several years and sludge disposal would become a major issue for theGovernment as well as WWTPs. As a technical preparatory work for above mentioned PhaseⅢ project, Wuhan Urban Drainage Development Co., Ltd (WUDDC) has conducted the initialbench-scale study and experiment on beneficial use of sludge, including agriculturalapplication as the fertilizer, extracting the protein from the sludge and applying the residue ingardening. The bench-scale study on extracting the protein from the sludge resulted inreduction of water content in the sludge to 45% (from 80% in the dewatered sludge), therebythe quantity of sludge to be disposed off at the landfill site or incineration plant would besignificantly reduced. The extracted protein from sludge could apply in the bricking and fire

fighting vesicant. So this study completely accord with the China’s government requirementsrelated to the sludge reduction, harmless, stability and reuse.

Wuhan’s strategic location along the Changjiang, commitment to improve wastewatermanagement and achievement of Government environmental policies provides anopportunity to invest in environmental management and boost the wastewater serviceprovision. Surveys show that both the poor and the non-poor are broadly in support ofenvironmental projects and consider improvements to their living environment as a priority toimproving their quality of life.

The Asian Development Bank (ADB) is administering the Water Financing PartnershipFacility (WFPF), a multi-partner cooperation platform for tying together various forms ofassistance to provide additional resources and technical support for the implementation of

ADB’s Water Financing Program. WFPF supports demonstration projects through in-countrywork for project preparation and implementation, capacity development in sectororganizations, and policy and institutional reforms to improve water resources managementand water services.

One of the components of WFPF to help improve program quality, that is “pilot anddemonstration activities” (PDA). The objectives of the PDA are: (1) to support newapproaches to processing and implementing ADB technical assistance and loan-financedinvestment projects, also new approaches in water sector policy development and sectorreform; (2) to improve and promote innovative the water invitation and implementationactivities from nongovernmental organizations (NGOs), development partners and localcommunities.





To expand the previous bench-scale study of beneficial use of sludge into a pilot-scale projectwith WFPF support, WUDDC has applied the PDA fund through ADB and finally signed theLetter of Agreement (LOA) with ADB on 15 September 2008.

1.2 Objectives and Scope of the PDA

The objective of this PDA is to conduct pilot-scale study following the bench-scale study, theextracting protein liquid from urban WWTPs. This pilot study is also aimed to the experimentof utilizing the residue applied to gardening earth, then setup demonstrating garden.

This study aimed to support and achieve the national sludge disposal ”reduction, stability,harmless, reusing” policy, utilizing the sludge to produce the economical hydrolyzed proteinliquid, and the residue (biosolid) as the gardening earth beneficial utilizing, then made thesewer sludge maximum utilized.

By end of June 2009, the PDA has undertaken all the following tasks mentioned in theMid-Term Report:

Task1: Pilot Study Parameters Selection sludge samples from the selected WWTP were

thoroughly analyzed as the basis for pilot study parameters selection, in addition to theachievements gained in the Bench-Scale Study;

Taks2: Pilot Study Sites Selection and Sludge Hydrolysis Processing proper sludgesource and hydrolysis site were selected based on the above parameters. As determined inInception Report, 6 tons wasted sludge from Nantaizihu WWTP was transported to WuhanJiabao Sugar Co., Ltd for hydrolysis experiment, with 0.9 tons protein liquid extracted, and1.98 tons hydrolysis residue produced;

Task3: Demonstration Gardening Application of Sludge Hydrolysis Residue/Biosolids a demonstrating garden has been constructed in Wuhan Erlangmiao WWTP to utilize thehydrolysis residue for various flowers and plants, and the growth of same plants in soils withdifferent ratio of hydrolysis residue are still being monitored and analyzed;.

Task4: Financial Viability and Environmental Sustainability Analyses were conductedthrough the end-users survey in June 2009 and laboratory analysis in May 2009,respectively.

1.3 Implementation Schedule

The PDA was further rescheduled to be implemented within a period of 7 months from 26November 2008 to 30 June 2009, with the specific activities completed as follows:

(a) Selection of WWTP and site for PDA: 26 November - 2 December 2008

(b) Inception Report: 9 January 2009

(c) Design of pilot-scale sludge processing and reuse facility: 10 December 2008 - 15January 2009.

(d) Construction of pilot-scale sludge processing and reuse facility: 26 January - March2009..

(e) Operation & monitoring of pilot-scale sludge processing and reuse facility: 18February 2009 - Jun 2009.

(f) Mid-Term Progress Report: 30 May 2009

(g) Conduct end-user surveys: 8 - 15 June 2009.

(h) Completion Report: 30 June 2009

The updated implementation schedule is shown in Appendix A .





The main responsibility for implementing this PDA is lodged with the Wuhan Urban DrainageDevelopment Co., Ltd (WUDDC), which will act as executing agency. The WUDDC is also theimplementing agency for the ongoing ADB Phase I and Phase II loan projects, andresponsible for operations and maintenance of wastewater treatment plants in Wuhan(except Hanxi WWTP).





SECTION 2 METHODOLOGY AND PILOT STUDY ACHIEVEMENT

2.1 Technical Principle for the Study

The characteristic of sludge from WWTP is mainly animalcules, protozoa, metazoans, algaeand few unknown organic and inorganic substances, and it contains high content of protein(50% to 70% in dry sludge). Hydrolyzed protein (Peptide) can be extracted from sludgethrough alkali hydrolysis. With the characteristic of froth, a lot of foam can be generated afterstirring and aeration from hydrolyzed protein, which can be then formed into ProteinFirefighting Powder through a serial process such as adding stabilization liquid, antiseptic,antifreeze. The hydrolysis biosolids consist of certain amount Nitrogen, Phosphorus, Kaliumand other organic elements, which can be utilized for gardening.

(a) The technology is to convert the sludge into two parts through hydrolysis: hydrolyzedprotein liquid and biosolids (70% volume reduction).

(b) Based on the high protein concentration feature of sludge, the technology extractsprotein, soluble organic and inorganic elements from the pollutants in sludge, withhigh temperature, high pressure and high concentration of alkali process. The finalproduct can be applied as firefighting powder, which is more environmental friendlythan conventional chemical powders.

(c) During the process, unknown organic matters, pathogeny animalcules, disease eggsare killed, so the there will be no biological pollution of the residue. The residuecontains only 45% water, which could be another source of urban gardening andlandscaping soil additive.

2.2 The Conclus ion of Bench-Scale Study

To verify the theory as mentioned above, Hubei University has been working together withWUDDC since 2006 and conducted bench-scale study with successful results.

During previous bench-scale study, the following results have been achieved:

(a) Identification of basic characteristic of sludge: water content 75~85%

(b) Identification of hydrolysis time: 6 hours.

(c) Identification of alkali dosage: 30% lime

(d) Temperature optimization: 121 degree CelsiusTotal 11 papers was published and 5 invention patents were awarded from the bench-scalestudy.

2.3 General Physical Progress

To further identify the market application feasibility, this pilot study was proposed and fundedby WFPF through ADB, as mentioned in Section 1. The Consultants developed the work planfrom November to December 2008, which is detailed in the Inception Report. This sectionsummarizes the pilot study activities conducted since project inception, and the issuesidentified.

Efforts on all the pilot study tasks have been made by the Consultants with the support fromWUDDC, Hubei University and relevant authorities:





(a) Sludge source selection at Nantaizihu WWTP, and sludge hydrolysis site selectionat WJSC

(b) Pilot study facility system design

1. Protein extraction facility lease negotiation and process design;

2. Hydrolysis residue (biosolids) gardening site design;

(c) Pilot study facility installation/construction

1. Protein extraction equipment modification at WJSC;

2. Garden construction at Erlangmiao WWTP of WUDDC;

(d) Protein extraction

(e) Sludge hydrolysis residue gardening application and planting

(f) Laboratory analysis of protein and hydrolysis residue and environmentalsustainability analysis

(g) Monitoring of gardening application(h) Biosolids end-user survey and financial viability analysis

2.3.1 Sites Selection for Pilot Study

2.3.1.1 Sludge Source Selection

With the study of current sludge status in WWTPs in Wuhan (see Figure 1 below), the Teamconfirmed the Nantaizihu WWTP for sludge collection during the inception stage, which hasbeen in operation since 2005 with stable waste sludge quantity and characteristics as suchconsidered the typical and stable sludge source for further application. Concurrence for thispilot study has been issued by the WWTP and WUDDC.

Total Dewatered Sludg e Quantitie s (kg/day)

0

10,000

20,000

30,000

40,000

50,000

60,000

70,000

H a n x i

S a n j i n t a n

N a n t a i z i h u

E r l a n g m i a o

S h a h u

L o n g w a n g z u i

L u o b u z u i

H u a n g j i a h u

H u a n g p u l u

Z h u a n k o u

T a n g x u n h u

C a i d i a n

B e i h u

H u a n g j i a d a w a n

WWTP

S l u d g e

M a s s ( k g / d a y )

0% VS Dest ruc tion

25% VS Destruct ion

50% VS Destruct ion





Figure 1. Preliminary Sludge Mass Estimates for All WWTPs

2.3.1.2 Sludge Hydrolysis Site Selection

During the bench study experimentation, it is observed that sludge hydrolysis requires hightemperature, lime dosing andfiltration. Considering the largequantity of sludge to be used in thepilot study, and budget constraint,lease a well established facility wasdetermined during the site selectionat the inception stage. With the localresource assessment and negotiation,the lease agreement was reachedwith Wuhan Jiabao Sugar Co., Ltd

(WJSC), for renting one set of itsprotein production facilities, withcapacity treatment approximately 6tons per day. Necessarymodifications and adjustments weremade on it prior to actual sludge

hydrolysis process.

2.3.1.3 Sludge Hydrolysis Residue Gardening Site

For the ease of gardening management and monitoring in long term, a permanent garden isproposed in Erlangmiao WWTP, the WUDDC Headquarter and where the project office is

situated. A reserved land was authorized at the inception stage by the WWTP and WUDDCfor this pilot study, and a 18 m2 garden was subsequently designed and constructed.

2.3.2 Pilot Study Facility System Design

Hubei University has extensive experience on the innovation of the technology applied in thisstudy and a well trained team during the previous bench-scale study, it is therefore entrusted

to develop the facility system design, with the services integrated in the 2 consultancyagreements with Prof. Li Yadong and Prof. Li Haibo on 5 November 2008.





Based on the system requirements described in Section 2.2.1, larger scale experimentation isrequired for the pilot study in terms of protein extraction and hydrolysis residue application.Investigations and initial agreements with WJSC and Erlangmiao WWTP of WUDDC wereconducted and reached during the inception stage, to (1) utilize the adequate steam andequipment in WJSC for hydrolysis and (2) construct a garden in Erlangmiao WWTP for

hydrolysis residue application.(a) Protein Extraction (Hydrolysis) Facility Design:

The existing facility in WJSC is extracting protein from corps, which needs modification forsludge hydrolysis. Upon the agreement entered with WJSC, one set of protein extractionfacility was leased to WUDDC for this pilot study, including:

a 10 tons Boiler

a 5m3 Hydrolysis Reactor

a 42m2 Frame Filer

Long tube concentrator

a 10m3 Filtration Buffer Tank

a 10m3 Storage Tank

a 15m3 Raw Material Mixing Tank

Feeding Pumps.

In accordance to the output of bench-scale study, the following protein extraction processwas developed:





Figure 2. Indicative Protein Extraction Process

(b) Garden Design:

To better compare the nutrient performance of hydrolysis residue with natural soil, a brickpartitioned, sand and crushed stone bedded garden is designed with a size of 6m by 3m,including 3 sections: a section at one end with 100% natural soil, a section at the other endwith 100% sludge hydrolysis residue, and the other section in the middle with natural soil and

residue ratio at 50% to 50%.There are 10 gardening plants selected based on the ecosystems in Wuhan area, and withthe characters of long term flowering and distinguished colors, such as Festuca Arundinacea Schred, Chrysanthemum Flower, Salvia Splendens, Catharanthus Roseus,Brassica Napus, Capsicum Annuum, Hibiscus Rosa-sinensis L., Euphorbia Mili, ScheffleraOctophylla etc.

Raw Sludge

HydrolysisReactor145

oC

Steam

Lime6%

Water40%

FrameFilter

HydrolysisResidue

(42-45% Water)

LiquidProtein

Concentrated LiquidProtein

(Long Tube 19o

Be)





Figure 3.

Festuca Arundinacea Schred

Figure 4.

Chrysanthemum Flower

Figure 5.

Salvia Splendens

2.3.3 Pilot Study Facility Installation/Construct ion

(a) Protein Extraction Facility Installation:

Due to the nature of available facility, the installation of protein extraction facility is mainlyadjustment and modification on the leased facility in WJSC, for the purpose of this pilot study.Following the process design, the lease agreement was entered with WJSC in February 2009and the leased facility was made available in March 2009. It was then cleaned and adjustedfor protein extraction from sludge.

Figure 6. Boiler Pressure Adjustment Figure 7. Frame Filter Cloth Replaced

(b) Garden Construction:

The civil works of the garden construction in Erlangmiao WWTP was contracted to WuhanKangxing Environmental Equipment Co., Ltd on 26 February 2009. The construction workscommenced in early March and completed in late March 2009. The construction process wassupervised by the property management team of WUDDC and the representatives from theWorking Group.

The biosolids was transported by WUDDC Production Department from storage site at WJSCto Erlangmiao WWTP on 20 March 2009. Gardening soil preparation was done by the

Contractor on 25 March 2009. Then gardening grasses and flowers were purchased on 20-25 April 2009.





Figure 8. Garden

2.3.4 Protein Extraction

Following the protein facility adjustment and modification in WJSC, 6 tons raw sludge wastransported by WUDDC Production Department from Nantaizihu WWTP on 18 March 2009.The protein extraction process was commenced on 19 March 2009 and 6 tons of raw sludgewere consumed during the 2 days extractions. The end products of the process are 900kgconcentrated liquid protein (long tube 19oBe), 3 tons hydrolysis residue.

Figure 9. Unpacked Raw Sludge at

Nantaizihu WWTP

Figure 10. Packed Raw Sludge Unloading at

WJSC





Figure 11. Hydrolysis Process Figure 12. Hydrolyzed Sludge Liquid

Figure 13. Filtration Figure 14. Raw Protein Liquid Filtered

Figure 15. Concentrated Protein Liquid Figure 16. Hydrolysis Residue

Process parameters were identified during the process:





Hydrolysis time: 2 hours

Alkali dosage: 6% lime

Hydrolysis temperature: 145oC

Identification of protein content: 27%

Water content in the hydrolysis residue: 45%

Foaming performance of protein:

- foaming stability time: more than 4 hours;

- foaming capacity: 120 times in volume

Characteristics of protein concrete (brick):

- water absorption rate: <10%;

- Weight ratio: 450kg;

- intensity: 0.5Mpa.

2.3.5 Laboratory Analysis of Protein and Hydrolysis Residue

(a) Protein Analysis

Protein analysis was conducted by Huibei University Laboratory for this study, prior, duringand after the protein hydrolysis process. The concentration of protein was measured by756MC UV-VIS Spectrophotometer the calculation of protein concentration in the driedsludge is through the equation: (Total protein / Total DS) ×100%.

The characteristics of the extracted protein are consistent with the result of Bench Study. It isconsidered that the protein extracted can be used as the source of firefighting protein powder,or protein concrete and brick, which needs further study on its application.

(b) Hydrolysis Residue Analysis

The hydrolysis residue laboratory analysis:

Identification of heavy metal ions: By Hubei Province Agricultural Technology Institute

Identification of fertilizer concentration: By Hubei Province Agricultural Technology

Institute

The result of heavy metal analysis is in Table-1 below:

Table-1 Heavy Metal Content in the Hydrolysis Residue（ mg/kg）

Heavy Metals Pb Cr Cd Hg As

Content in the Sample 42.6 112.3 0.32 1.42 8.29

Content Limits in GB4284-84:

Standard for Pollutants Control in

Sludge Agricultural Application

300 600 5 5 75





Available Boron

(mg/kg)0.60 0.92 0.76 0.13

Available

Molybdenum (mg/kg)2.50 3.04 2.77 0.72

Organism (%) 28.75 30.70 29.73 23.00

pH 7.66 7.53 7.60 13.10

It is noticed that the Total N is significantly lower in the hydrolysis residue than that in thesludge from Nantaizihu WWTP, which indicates most N was extracted from the sludge in theform of protein liquid.

The comparison also implies that the sludge from Nantaizihu WWTP has some level ofnutrients and the heavy metals content is also lower than the control limits for agricultural

application, however, it is considered not suitable as fertilizer. The reasons are (1) thenutrients content in the sludge is not as high as normal fertilizers; (2) direct application ofsludge will cause odor problem; (3) continuous application will cumulate heavy metals incrops and the downstream of food chain.

The hydrolysis residue is with certain level of nutrients content, which can be considered asbiosolids to be mixed with natural soil for gardening application. However, the result alsoshows the hydrolysis residue is of high pH, which may have some impacts on the plantsgrowth. Therefore, further study on neutralization of the hydrolysis residue was conducted.

(c) Neutralization of Hydrolysis Residue

Most of plants are favoring the soil condition close to pH=7, therefore, the neutralization ofhydrolysis residue was designed as follows: (1) water dilution; (2) mixture with garden soil; (3)mixture with natural soil; (4) piling for natural dilution by rain water. Seeds germinating rate inthe neutralized hydrolysis residue samples was compared with that in the original hydrolysisresidue.

The neutralization study shows:

- The water dilution is the most efficient way to neutralize the high pHhydrolysis residue, but not practicable;

- The hydrolysis residue mixture with gardening soil or natural soil canneutralize the high pH after around 15 days with a preferable ratio ofhydrolysis residue less than 50%;

- Piling hydrolysis residue outdoor with some rainfalls can neutralize in about6 days;

- Except for alkali favored seeds, all others can germinate better in the above4 neutralized soils than in the original hydrolysis residue.

Conclusion was then drawn that the hydrolysis residue can be used as biosolids afterneutralization, and water can reduce the neutralization process time. The garden wastherefore designed with water spray system.

2.3.6 Sludge Hydrolysis Residue Gardening Application

The planting of grasses and flowers in the garden was completed on 26 April 2009. Ten (10)grasses and flowers were planted in each section. The 10 grasses and flowers were at thesame conditions before planting in each section of the garden, which has been monitored by





the Consultants with a weekly basis since May 2009. Following factors will be recordedduring the monitoring for each grass and flower for comparison: height, size and color ofleaves, size of flowers.

The monitoring will continue after this pilot study, to provide technical support and data for ADB Phase III preparatory works and implementation.

Figure 17. Over View of Planted Garden Figure 18. Section with Natural Soil

Figure 19. Section with Mixed Soils Figure 20. Section with Hydrolysis Residue





2.3.7 Gardening Record

The monitoring of gardening applicaiton is scheduled in a weekly basis, and conducted by thetwo project secretaries with guidance from researchers and assistant researchers. Therecords are summarized as below:

2.3.7.1 Soil pH Monitoring

Table-3 Sludge Hydrolysis Residue Gardening Application pH Monitoring Records

pH Initial

pH

pH after

one

week

pH after

two

weeks

pH after

three

weeks

pH after

four

weeks

pH after five

weeks

Irrigation Nil Once/day Once/day Once/day Once/day Nil

Hydrolysis Sludge

Residue Section8.5 7.0 6.9 6.9 6.9 6.9

Mixture Section 7.8 6.9 6.9 6.9 6.9 6.9

Natural Soil

Section7.1 6.9 6.9 6.9 6.9 6.9

2.3.7.2 Plants Chlorophyll Content Monitoring

According to the nature of chlorophyll, absorption of visible light, the spectrophotometer is

used to determine the chlorophyll content in the 10 plants. Following equation is employedduring the analysis:

)/( gmgSampleof Weight

Times DilutionPlants from Extracted Liquid of VolumeionConcentrat lChlorophyl

Content lChlorophyl

××

=

The analysis result shows that the chlorophyll content in the Chrysanthemum planted insludge hydrolysis residue section is 25%, 26% and 22.5% at its upper, middle and lower bodysegments, which are similar to the one planted in natural soil section and in mixed soilsection.

Conclusion:

During the 5 weeks monitoring, all the 10 plants are growing well in the sludge hydrolysisresidue section, as well as in the mixed section, such as leaf color, plant height, etc. nosignificant difference with those in the natural soil section. It is therefore concluded that theSludge Hydrolysis Residue can be reused as gardening soil.





2.3.8 End-Users Survey

2.3.8.1 Survey Plan and Questionnaire Design

The end-users of this pilot study are mainly public and private gardening organizations forhydrolysis residue application. A survey plan and associated questionnaire were developed

by the Consultants, and attached as Appendix C1.

2.3.8.2 Survey Implementation

The survey was conducted on 8-15 June 2009 with potential end-users Qingshan GardeningCompany and Wuhan Lumeidi Environmental Engineering Co., Ltd. The survey result issummarized below while the questionnaire feedbacks are shown in Appendix C2:

1. Garden soil annual procurement budget: RMB100,000 ~ 500,0002. The requirements of soil nutrient content: nitrogen, phosphorus and potassium-based3. Soil pH requirement: acidic4. Soil storage requirements: open-air, general warehouse stacking

5. Acceptable price of the soil: RMB80 ~ 180 / tonFrom the above findings of end-users come to the conclusion as follows: Sludge HydrolysisResidue after the extraction of protein residues to the end for the market, but also a certaindegree of economic efficiency, but need to adjust pH.

2.3.9 Financial Viability Study

The financial viability study was conducted by the Consultants based on the end-user surveyand market information collected, which has the following conclusions:

2.3.9.1 Sludge Hydrolysis Residue/Biosolids

The process employed by the PDA produces 150kg hydrolysis residue from one ton sludge,

with an estimated market price around RMB100-120/ton as gardening soil including transportcost, according to the above end-user survey. A net profit around RMB20-30/ton residue isexpected.

Since the WWTPs in Wuhan are currently dumping waste sludge into landfills with a feecharged at RMB50/ton, it’s therefore RMB50/ton saving for WUDDC in addition to the netprofit above.

At the same time, its environmental impact is significant: there is no waste water, wasteresidue, exhaust emissions in the production process, so it is total environmentally friendlyprocess. In addition, the hydrolysis residue can be directly used as gardening soil, withoutbiological contamination after the high temperature treatment process, while the chemical itsheavy metal ion content is well below the national standard of agricultural application.

2.3.9.2 Protein Extracted

Currently the extinguishing powder for petrolium, chemical, oil depots, airport fire-fighting ismainly chemical foam (NaHCO3 or NaCl), plant protein or animal protein powders. In whichthe animal protein powder will produce offensive odor and air pollution during firefighting, so itis in the process being prohibited. Although plant protein powders are good for fire-fighting,but the dietary protein source is limited and causing high price of the protein product (approx.RMB4,500 / ton, compared the sludge liquid protein for RMB2,500 / ton), so it is not favoredby fire-fighting industry. Therefore, sludge protein has a bright market future with its low priceand environmentally friendly characteristics.

There is 150kg liquid protein extracted from one ton sludge, with a net profit estimated at

around RMB 600/ton liquid protein. Further study on capability of extracted liquid protein fromindustrial application and its market value will be conducted as another project.





2.4 Issues Identified During Pilot Study

Since the PDA commenced in November 2009, several issues have been encounteredduring the study, which are summarized below:

(a) The pilot scale equipment is too expensive to purchase under the dedicated

allocation of PDA budget, so is the system operation space required;

(b) Due to the budget reason as above, the PDA is only capable to conduct the pilotscale study on protein extraction and hydrolysis residue gardening application,while leaving the exploration of protein application for future study;

(c) The hydrolysis residue gardening application proceeded with flowers purchasedfrom market rather than seeds, which may cause the comparison amongdifferent soils not very distinct.





SECTION 3 PROJECT MANAGEMENT

3.1 Project Management Structure

3.1.1 Background

During the inception stage of this pilot study, WUDDC established a working groupcomprising people from management and relevant departments of WUDDC, which wassupported by the consultants and specialists engaged for the Project. The keyrepresentatives from the WUDDC are currently implementing the loan project, who haveacted as key members of the working group for this PDA. The working group composition isshown below:

Organization Name Title

Mr. Wang Changqing GM, Director of PDA Working Group

Mr. Tian Zhongkai Chief Engineer, Technical Advisor of Working Group

Working

Group

from WUDDC Mr. Gu Jianxin Deputy GM, Executive Director of Working Group

Mr. Tommy Zhang Team Leader, International Wastewater Engineering

Specialist

Mr. Li Yadong Professor, Hubei University, Domestic Wastewater

Engineering and Sludge Disposal Specialist

Mr. Li Haibo Professor, Hubei University, Domestic Wastewater

Engineering and Sludge Disposal Specialist

Ms. Liu Xiaoyan Head of Chief Engineer Office, Assistant

Researcher

Ms. Li Yan Assistant Researcher

Ms. Wang Haibo Secretary, Translator

Consultants

Mr. Zhong Hao Secretary and Translator

3.1.2 Responsibilities

The responsibilities of each member of the working group were described in the Appendix Aof Inception Report.

There were responsibilities variation and breakdown made in March 2009 for the WorkingGroup from WUDDC, with the following update:





Name Title Responsibili ty

Mr. Tian Zhongkai Chief Engineer,

Technical Advisor

of Working Group

responsible for day-to-day technical management of

the Pilot Study and coordination with Consultants.

Mr. Gu Jianxin Deputy GM,

Executive Director

of Working Group

responsible for liaison with ADB for project

management.

3.1.3 Tasks Undertaken

The Working Group and its Consultants have contributed to the pilot study successfully in

three stages:

Inception Stage: tasks undertaken during the inception stage by the Team include a reviewof project documents and previous bench-scale study output to ascertain the current status ofthe project, conduct interviews and meetings with WUDDC and the relevant agencies tocollect information and establish working relationships, selection of sludge from NantaizihuWWTP and pilot study site at WJSC, design development of pilot-scale protein extractionfacility and preparation of Inception Report.

Inception to Mid-Term Stage: tasks conducted since the inception by the Team consist ofmeetings with relevant organizations during the design of pilot-scale sludge protein extractionfacility and gardening facility; installation and commissioning of the facilities, operation;packaging and transporting the sludge, protein extraction, laboratory analysis of protein

extracted and the hydrolysis residue, garden construction and demonstration, reporting.

Mid-Term to Final Stage: as most of technical tasks have completed, the Team wasfocusing on the monitoring of gardening application and biosolids end-users survey duringthis stage. Financial viability analysis and final report preparation were undertaken.

3.2 Reporting

There are total three reports prepared by the Consultants with the support of Working Group:

(a) Inception Report: describes the project background information, project teamestablishment, and planning for the pilot study. It was initially prepared in January2009 and reviewed by ADB mission in March 2009, and subsequently submittedtogether with Mid-Term Report on 29 May 2009;

(b) Mid-Term Report: reports the physical and project management progress of thepilot study. It was submitted on 29 May 2009;

(c) Final Report: summarizes the overall pilot study physical and project managementprocess, concludes the outputs, the outcomes, and the issues identified. It is to besubmitted on 30 June 2009.

3.3 WFPF Funds Utilization

In accordance to the Letter of Agreement signed between ADB and WUDDC, there is total

USD50,000 grant from WFPF allocated for this PDA, while WUDDC provides counterpartfunds for necessary activities such as office, transportation, translation, etc with a budget ofUSD20,000. The utilization of WFPF grant is through four (4) milestone disbursements:





Advance, Inception Report, Mid-Term Report and Final Report. The up to date fundsutilization is shown in the SOE in Appendix D.

3.3.1 Contract Awards and Expenditure

3.3.1.1 Contract Awards To-date

During this pilot study, totally five (5) contracts were awarded with accountable USD38,600 toWFPF Grant, while another USD11,400 from WFPF Grant is for the salary paid to assistantresearchers and project secretaries. Details are as follows:

(a) 3 consultancy services agreements were signed between WUDDC and 3wastewater specialists on 5 November 2008, with total amount of USD29,000.

(b) After consulted with ADB, 4 services agreements were signed between WUDDC

and 2 assistant researchers and 2 secretaries on 2 June 2009 to meet the

contractual requirements, with total amount of USD11,400

(c) 1 design services agreement was signed between WUDDC and Prof. Li Yadong,Prof. Li Haibo, with total amount of USD9,600, including the 2 agreementsbelow:

the equipment lease agreement between WUDDC and WJSC

The civil contraction contract between WUDDC and Wuhan KangxingEnvironmental Equipment Co., Ltd.

3.3.1.2 Expenditure To-date

By 30 May 2009, expenditure payable USD50,000 from WFPF Grant has occurred, with thedetails shown below:

(a) Expenditure Paid

1. USD45,000 WFPF fund was paid to consultants during the inception stage(refer to SOE No.1 of Inception Report and SOE No.2 of Mid-Term Report);

(b) Invoices and Receipts to be Paid (refer to SOE No.3 of this Final Report)

1. Invoices collected from 3 specialists

a. Mr. Tommy Zhang: USD51,00, invoice dated 30 June 2009;

b. Prof. Li Yadong: USD18,00, invoice dated 30 June 2009;

c. Prof. Li Haibo: USD18,00, invoice dated 30 June 2009.

2. Receipts to be collected after salaries paid

a. Ms. Liu Xiaoyan: USD1,100

b. Ms. Li Yan: USD1,100

c. Ms. Wang Haibo: USD800

d. Mr. Zhong Hao: USD800

3.3.2 Disbursement

3.3.2.1 Disbursement To-date

As of 30 June 2009, there has been USD20,000 WFPF fund disbursed.





December 2008, USD20,000 advance payment was disbursed from ADB toWUDDC account for project commencement.

3.3.2.2 Disbursement during the Reporting Period

There was no disbursement since inception due to the late submission of the Inception

Report.





SECTION 4 OUTPUTS AND OUTCOMES

4.1 Outputs

The objectives set forth in the LOA “Beneficial uses of sludge determined; financial viabilityand environmental sustainability assessed” have been achieved during this seven monthsPDA.

The PDA is aiming the pilot study for (1) protein extraction from sludge; (2) utilization ofbiosolids for landscaping; and related financial and environmental sustainability. The pdaoutputs are converting all the waste sludge into commercial products through (1) proteinliquid for commercial use, upon further follow up study; (2) biosolids non-hazardous test forlandscaping as commercial product; (3) end-user survey for the biosolids produced.

4.2 Outcomes

As the first PDA project WUDDC has ever conducted, the management has learnt theprocedures from this project, and been familiar with this particular type of WFPF grant forfuture pilot studies.

In supporting with WUDDC’s current projects funded by ADB, the PDA has gone further intopilot scale to study the application of alternative technologies in addition to the sludge studyof Phase II, and particularly provide a clear picture and technical solution for Wuhan sludgemanagement strategy for the on-going ADB Phase III PPTA. WUDDC will then benefit fromthe 3 ADB projects for improving not only wastewater and sludge treatment capacity, but alsoplanning and management capability for more efficient, reliable wastewater and sludgemanagement services, and effective protection of environment in Wuhan city.

4.3 Impacts

With the outputs above, the waste sludge is 100% utilized as protein liquid and biosolids.Therefore, the impact to the environment by waste sludge will be minimized and the currentlandfill plants can serve longer period without receiving the 500 ton/day or more sludge fromWWTPs. Wuhan city will therefore have an improved and cleaner environment.

4.4 Further Actions

4.4.1 Follow-Up of Pilot Study Achievement

Further analyze and study the Sludge Quality Report of all the WWTPs in Wuhan;

Tidy up and analyze all the raw data of pilot study, follow up the primary

achievement, further discuss the most suitable manner of beneficial use of sludgein Wuhan;

Conduct a pro-seminar, call the correlative consultants and other experts togetherto analyze the primary achievement, and explore more ideas of the application ofhydrolyzed protein.

A long term gardening monitoring mechanism is to be established indemonstrating the beneficial use of sludge and supporting the ADB Phase IIIpreparation and implementation.

4.4.2 Further Pilot Study on Protein Liquid Industrial Application

As identified during this PDA, protein liquid industrial application has not been studied due tolack of funds. Based on the bench study and knowledge of protein market, it is consideredthat the protein liquid extracted from sludge will have much more commercial value than the





biosolids. It is therefore suggested WUDDC to apply another PDA project for protein liquidindustrial application pilot study, including (1) permanent pilot system purchase, installation,operation and maintenance; (2) beneficial use of extracted protein as the source for vesicantand further demonstration.

To resolve the issue of fund for further study on extracted protein application, the Consultant

has suggested the Working Group and WUDDC to consider further financing, preferably from ADB as the continuation of this PDA.





APPENDIX A UPDATED IMPLEMENTATION SCHEDULE



标识号

Task Name 工期

1 Overall Schedule 156 days

2 Project Preparation 5 days

3 Selection of WWTP and site for PDA 5 days

4 Project Inception 29 days

5 Prepare Inception Report 12 days

6 Inception Report Due 0 days

7 Project Inception to Mid-Term 146 days

8 Design of pilot-scale sludge processing a 27 days

9 Construction of the facility 46 days

10 Operation & monitoring of the facility 96 days

11 Prepare Mid-Term Progress Report 10 days

12 Mid-Term Report Due 0 days

13 Project Completion 22 days

14 Conduct End User Survey 5 days

2008年年年年11月月月月26日日日日 2008年年年年12月月月月2日日日日


2009年年年年1月月月月9日日日日




M E B M E B M E B M E B M E B M

第四季度第一季度

200

Appendix A Implementation Schedule

Wuhan PDA - Beneficial Use of Sludge page1



标识号

Task Name 工期

15 Prepare Project Completion Report 12 days

16 Completion Report Due 0 days

17 Project Completion Target Date 1 day

M E B M E B M E B M E B M E B M

第四季度第一季度

200

Appendix A Implementation Schedule

Wuhan PDA - Beneficial Use of Sludge page2





APPENDIX B STAFFING SCHEDULE



Appendix B Staf fing Schedule

WEEK

Nov-08 Dec-08 Jan-09

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2INTERNATIONAL

Tommy ZHANG IndividualInternational Wastewater Engineering Specialist /

Team Leader

SUBTOTAL

DOMESTIC

Li YadongHubei Uni

Domestic Wastewater and Sludge Disposal

Engineering Specialist

Li Haibo Hubei Uni

Domestic Wastewater and Sludge Disposal

Engineering Specialist

Liu Xiaoyan WUDDC Assistant Researcher

Li Yan WUDDC Assistant Researcher

Wang Haibo WUDDC Secretary / Translator

Zhong Hao Individual Secretary / Translator

SUB-TOTAL

TOTAL

LEGEND:

FIELD - FULL TIME (INTERNATIONAL AND DOMESTIC SPECIALISTS)

HOME OFFICE - (INTERNATIONAL SPECIALISTS), WORKING TIME RANGING FROM 1 DAY TO 5 DAYS DEPENDING ON TASK REQUIR

WORK IN FIELD BUT AWAY FROM PROJECT OFFICE (DOMESTIC SPECIALISTS), WORKING TIME RANGING FROM 1 DAY TO 5 DAYS

Note: Field work means works done at a place other than the consultant's permanent office or duty station.

NAME FIRM POSITION Feb-09 Mar-09 Apr





APPENDIX C1 END-USER QUESTIONNAIRE



APPENDIX C1

END-USER QUESTIONNAIRE

General Organization Information

1． Name:

2． Address:

3． Contacts:

4． Number of Employees:

5． Annual soil procurement in the last 3 years (tons / year):

6． The highest, and the lowest unit prices of soils procured:

7． Planted / cultivated plant species:

8． Plant cultivation / sales (strains / year):

9． Will you accept the municipal WWTPs’ sludge hydrolysis residue (heavy metals

and nutrients analysis results attached) as the raw material of gardening soil?

Gardening Plant Species:

1． Nature of business?

A． Utilities

B． Profit-oriented enterprises

2． How much of your annual budget for purchasing soil?

A． Below 100,000 Yuan

B． 100,000-500,000 Yuan

C． 500,000-1,000,000 Yuan

D． Over 1,000,000 Yuan

3． What kind of gardening plant is in you main business?

A． Horticultural plant

B． Garden shrubs

C． Large-scale horticultural plants

D． Others

4． Which zone of following do your plants belong to?

A． Frigid zone plant

B． Mesotherm plant

C． Subtropical plantD． Tropical plant

E． Plant along the Yangtze River and Han River basins

F． Others

5． How many species of plant do you have?

A． below 10

B． 10-50

C． 50-100

D． over 100

Requirements of Nutr ients in Soil

1． The basic requirement to soil nutrient (Please list the specific requirement of

content, unit: mg / kg )



A． Mainly N

B． Mainly P

C． Mainly K

D． Balanced type (N, P, K)

2． The basic requirement to alkalinity or acidity of the soil (Please list pH range)

A． AcidophilicB． Neutral

C． Subalkalic

3． The basic requirements to the soil package:

A． None

B． Plastic package

C． Paper package

D． Others

4． The basic requirements to storage conditions:

A． None

B． Enclosed storage

C． Field piling

D． General storage piling

E． Aeration covered piling

F． Others

Acceptable Soil Pr ice

1． How much could your company accept (excluding transport, according the

dofferent N, P, K content to fill differenet answers.)?

A． 100 Yuan/tonB． 200 Yuan/ton

C． 500Yuan/ton

D． above 800 Yuan/ton

WUDDC WWTPs’ Sludge Hydrolysis Residue Analysis Results:

Heavy Metal Content in the Hydrolysis Residue（ mg/kg）

Heavy Metals Pb Cr Cd Hg As

Content in the Sample 42.6 112.

30.32 1.42 8.29

Content Limits in GB4284-84: Standard

for Pollutants Control in Sludge

Agricultural Applicat ion

300 600 5 5 75



Nutrients Content in the Sludge and Hydrolysis Residue

NutrientsSludge before

Hydrolysis

Sample 1 Sample 2 Average

Hydrolysis

Residue

Total N (%) 2.26 2.62 2.44 0.46

Total P (%) 0.86 0.67 0.77 0.44

Total K (%) 0.60 0.84 0.72 8.78

Alkal i-hydrolyzed

Nitrogen (mg/kg)904.40 1083.95 994.18 70.60

Avai lable

Phosphorous

(mg/kg)

37.62 32.20 34.91 68.60

Avai lable

Potassium (mg/kg)764.60 432.50 598.55 95.90

Slow-release

Potassium (mg/kg)76.90 563.50 320.20 /

Avai lable Copper

(mg/kg)10.40 1.20 5.80 0.80

Available Zinc

(mg/kg)14.50 13.30 13.90 1.40

Avai lable Iron

(mg/kg)115.20 227.40 171.30 7.50

Avai lable

Manganese (mg/kg)70.90 65.70 68.30 8.20

Avai lable

Magnesium (mg/kg)333.80 241.40 287.60 0.036

Avai lable Calcium

(%)0.69 0.54 0.62 0.27

Available Sil icon

(%)0.06 0.10 0.08 0.012



Available Sulfur (%) 0.07 0.09 0.08 0.64

Avai lable Boron

(mg/kg)0.60 0.92 0.76 0.13

Avai lable

Molybdenum

(mg/kg)

2.50 3.04 2.77 0.72

Organism (%) 28.75 30.70 29.73 23.00

pH 7.66 7.53 7.60 13.10





APPENDIX C2 FEEDBACK OF END-USER QUESTIONNAIRE





APPENDIX D STATEMENT OF EXPENDITURES



Current

Period

Cumulative

From Start

to Current

(b)

FUNDS RECEIVED (c) 20,000.00

1. Consultant/Specialists and Related

Expenses:

1.1 Wastewater Engg. Specialist (Int'l) 17,000.00 17,000.00 17,000.00 -

1.2 Wastewater Engg. Specialist

(Domestic)12,000.00 3,000.00 12,000.00 -

1.3 Design of Pilot Plant 3,000.00 - 3,000.00 -

1.4 Pilot Plant Devices Installation 6,600.00 - 6,600.00 -

4. Service Contractor

4.2 Assistant Researcher 6,600.00 2,200.00 6,600.00 -

4.3 Secretary 4,800.00 1,600.00 4,800.00 -

GRAND TOTAL (d) 50,000.00

FUNDS BALANCE (c-d) (30,000.00)

Tommy Zhang Wang Changqing

Project Name: PRC-Pilot Study on Beneficial Use of Sludge

s ere y cer e a e a ove amoun s ave een pa or e proper execu on o e

Technical Assistance activities, all within the terms and conditions of the Technical Assistance

Agreement.

(US Dollars)

All supporting documentation substantiating these expenditures will made available upon request

by ADB

Form 15

Item or Category

Approved

Cost

Estimates

(a)

Actual ExpendituresBalance of

Cost

Estimates

(a-b)

Project Financial Status for the period: 30 May - 30 June 2009

LIQUIDATION OF ADVANCE - PROJECT FINANCIAL STATUS (SOE)

Water Financing Partnership Facilit y

PILOT AND DEMONSTRATION ACTIVITY

PRC PDA: Sludge Beneficial Uses (Final Report)

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