The Biobed® Advanced system is cheaper and more …Biobed... · The Biobed® Advanced system is...
Transcript of The Biobed® Advanced system is cheaper and more …Biobed... · The Biobed® Advanced system is...
The Biobed® Advanced system is cheaper and more reliable
Biobed® SMART and Memthane®
Novel Reactors and their superior control
Lyon; November 27, 2012; 13:45 Jan Pereboom
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Contents
1. Introduction
2. The Biobed® Advanced granular system
3. The Biobed® SMART reactor control system
4. The Memthane® AnMBR
5. Conclusions
Biothane: competence centre of Veolia Water
Veolia Water • Revenues 12.6 bln€; 69 countries; 97,000 employees (2011)
• Drinking water for 103 mln consumers; sewage of 73 mln inhabitants
Veolia Water Solutions and Technologies (VWS) • Contracting and equipment; 350 proprietary technologies
• Revenue 2.3 bln€; 135 business units; 10,800 employees
Biothane • World market leader for Anaerobic industrial wastewater treatment
• In 35 years more than 530 references were established
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Anaerobic versus Aerobic WWT
45% Carbon Dioxide
50% Biomass
BOD Air (O2)
100 kg COD to Aerobic
BOD (25OC – 35OC)
75% Biogas (75% Methane)
5% Biomass
100 kg COD to Anaerobic
Aeration
(100 kWh)
Sludge, 30-60 kg
Heat loss
2-10 kg COD
CH4 26 - 30 Nm3 CO2 5 - 12 Nm3
Sludge, 5 kg
10-20 kg COD
1 kg COD removed 0.35 Nm3 CH4 or 3.8 kWh
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Biothane’s Granular Technologies
Biobed® Advanced UASB or EGSB • Granular Sludge Bed
• Up to 30 kg COD/m3/d
Biobed® Modular Plant • Compact off-site construction
• 50 ~ 200 m3 reactor volume
• 0.5 ~ 4.0 tCOD/day
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Biothane technologies; non-granular Biobulk CSTR • Solid waste digestion
• With or without sludge recirculation
• Suitable for high COD / SS / FOG waste(water)
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Upthane™ • Municipal UASB technology for
tropical climates
• Novel design
Memthane® Anaerobic MBR • New technology for high strength wastewater
• Using Cross-flow UF membranes
• High COD / SS removal efficiencies
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Pomethane® CSTR • Palm Oil Mill Effluent
Biothane UASB vs. Biobed® EGSB
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Upflow Anaerobic Sludge Blanket • 10 ~ 15 kgCOD/m3d; 8 ~ 10 meter height
Expanded Granular Sludge Bed • 15 ~ 25 kgCOD/m3d; 10 ~ 20 meter height
500 references
COD reduction rate EGSB is equal or lower but
Volumetric loading rate is 2-3 x higher
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Biothane UASB Biobed® EGSB
Biothane UASB vs. Biobed® EGSB
Biobed® Advanced Anaerobic granular technology at the next level
Reduced investment and operating costs
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Combining the best of both
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Solution Biobed® Advanced
Advantages of UASB
Advantages of EGSB
Challenge: combining the best of UASB and EGSB
• Excellent performance • High COD removal efficiency • Good biomass inventory
• Reduced investment costs • Higher volumetric loading rates (2-3 times) • Taller reactors (2-3 times) • Smaller footprint
Objectives of Biobed® Advanced & SMART
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80 %
hydraulicbuffer tank
Anaerobic reactor
Aeration tank
Hydraulic buffer tank
Anaerobic reactor
Aeration tank
Dynamic control
85 % 10 ~ 25% smaller
Improving the anaerobic performance • Thus reducing investment and operating costs
Improving COD removal rate
Novel Biobed® Advanced Settler
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Patented new settler and reactor design
Multi level biogas separation
TTS; Tilted Tube Separator on top of the settler • Increasing the settler surface area for
• Improving the retention of biomass and SS in the reactor
Robust effluent pipes which replace conventional effluent gutters
Based on fundamental research
5 years research by committed team • Many with more than 25 years of experience
Lab scale testing
Hydraulic model testing at 1:1 scale
Pilot scale testing at 7 m3
Full scale testing and data gathering
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Biothane Pilot plant 2011TSS Effluent vs Vl settler
TSS Effluent
Study of operational data Biobed++ referenc Pilot plant results paper wastewater
Effect of liquid velocity in Advanced settler on effluent SS
• Up to 19 m/h no effect designing at higher upflow velocities
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Study of operational data Biobed++ referenc
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Testing results paper wastewater
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Biothane Pilot Plant 2011Volumetric loading rate
Pilot plant
Full scale Biobed
Full scale UASB
Pilot: 12.8 kg SCOD/m3.d
BB: 8.9 kg SCOD/m3 .d
UASB:4.28 kg SCOD/m3 .d
Biobed® Advanced pilot 140% loading as compared to EGSB full scale Biobed® Advanced pilot 300% loading as compared to UASB full scale
Advanced Pilot
EGSB full scale
UASB full scale
Biobed® Advanced; smaller settler and reactor
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Smaller settler height • 1.0 meter lower
• Same net volume loading rate
• Higher gross volumetric loading rate
Higher applicable liquid upflow velocity • Smaller required settler area
Reduced settler price
Substantial influence on Capex and Opex • Lower energy demand
1.0 m
net reactor volume
Biobed® Advanced; Easy effluent pipes
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Novel effluent pipes replacing conventional gutters
Less critical in levelling • Reduces short circuiting risk
Less maintenance
Biobed® Advanced; flexible reactor height
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Wastewater characteristics (process) determines reactor height
Complex: Biobed® Advanced UASB up to 6 ~ 10 meters height
Simple: Biobed® Advanced EGSB 10 ~ 20 meters height
Both either in steel or concrete reactors; round or square
Biobed® Advanced; Optimizing investment and operating costs
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Compact settler result in more flexible reactor design
Optimal size: Diameter = 0.8 x Height
Tall is more costly and requires more energy
Biobed® Advanced; Reduced operation costs
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Novel superior settler • Excellent biomass inventory
• Stable growth of granular biomass
Therefore • High COD removal efficiency (long SRT)
• Less chemical consumption; pH, nutrients, anti-foam
• Less operator attention
Overall lower operating costs • Smaller aerobic post treatment
• Less overall maintenance cost
Confirmed by numerous full scale results
Novel Biobed® SMART control system • Will further improve stability and performance
Biobed® Advanced; Resume of advantages
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Improved performance • Based on fundamental research
• Improved superior COD removal efficiencies
• Excellent biomass inventory
• No odour emission
Tailor made design • Flexible reactor height
• Flexible in construction; round steel or square concrete
• Easy effluent pipes
Reduced Capex and Opex • Small compact settler and small reactor
• Low chemical consumption
• Reduced aerobic post treatment
• Small foot print
A proven track record
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Proven Innovation • 25 full-scale Biobed® Advanced plants
• 5 years of full-scale industrial operation
• 2 pilot plant testing locations
• Overall track record of 530 plants
Implemented in • Pulp & Paper
• Chemicals and PTA
• Food: Dairy, Sugar, Potato, Soya
• Brewery & Distillery
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Nov-07 Jun-08 Dec-08 Jul-09 Jan-10 Aug-10 Feb-11 Sep-11 Apr-12 Oct-12
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Date
COD reduction89%
80%
78%
Design
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Biobed® Advanced full scale; chemical case
Very high COD removal efficiency for PTA wastewater
Steady biomass increase observed
Biobed®SMART reactor control system (1)
Sludge Management and Reactor Control Techniques
Objectives : • Achieve more stable reactor operation
• Achieve higher COD removal efficiency
• Reduce operating costs
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“Real time video from inside the anaerobic reactor”
Development of Biobed® SMART
SMART control box 1. SMART process indicators (early warning)
Online continuous insight for operator in process performance
Based on a combination of different online measurements
Red / green lights to indicate process performance
2. SMART process control loop
Stable process load (dynamic control)
Optimized nutrient dosing
pH optimization
Temperature optimization
3. SMART imaging
Online view on biomass granules in reactor
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Biobed® SMART Process Indicators
Capacity indicator defines if spare capacity is left in the plant (in situ biomass activity test) • Based on patented measuring principle
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Calculated Load Biogas
Biobed® SMART control loop
Pilot plant results with and without Dynamic Control
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Normalized gas production
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Fluctations in gas production SMART Load control
Normalized gas production
Load
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Variation + 25%
Dynamic Control: Client Case-study
Fruit juice factory in the Netherlands • Flow 600 m3/day
• Load 1.5 ~ 2.0 tons of COD / day
200 m3 Equalisation tank
200 m3 storage tank
3 x 50 m3 Biobed® Modular Plant
High fluctuations in load, flow and low nutrient content
Resulted in poor performance and high costs
From: * Warmenhoven, J.W. and Spanjers, H. (2011). “TOC based control of anaerobic
reactor treating wastewater from a fruit juice packaging factory.” Water Practice & Technology 6 (2)
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Dynamic Control: Client Case-study
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Net Biomass growth
Reduction in N-consumption despite of increased average load
Stable operation reduced operator and analysis cost
+ 11% -40% +32% -56% -43%
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Biobed® SMART; Advantages
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Lower Capex • Smaller required reactor volume; handling more load
• Less hydraulic buffer volume
• Reducing Carbon Footprint
Reduced Opex • Lower post treatment cost; slightly more biogas
• Lower chemical costs; pH and Nutrients
• Better sludge inventory
• Less maintenance/operator costs
Quality improvement • Better effluent quality
• Early warning system for possible reactor upset
• Improve reliability and availability
• Reduced start-up time
Memthane® The preferred solution for high-strength wastewaters
resulting in crystal clear effluents
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Drivers for Anaerobic MBR (1)
Specific wastewater characteristics
FOG (Fat, Oil & Grease) and LCFA (Long Chain Fatty Acids)
• Hamper granulation in UASB or EGSB
High concentrations (COD + salts); e.g. Whey & Thin Stillage
• Un-diluted: no granulation in UASB due to high HRT, salts
• Diluted: too large UASB reactor volume
• Solution often low loaded CSTR systems
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Drivers for Anaerobic MBR (2)
Higher loading rate in CSTR digester achieved by
• Uncoupling of HRT and SRT by use of membranes
Higher COD removal efficiencies & clear effluents
• Smaller post treatment; more compact & less energy consumption
• Higher digestion efficiency, more biogas
• Effluent free of suspended solids; easy nutrient recovery
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Memthane® step-by-ste
Conditioning of high- strength wastewaters.
Influent is fed to the anaerobic bioreactor where the organic components are converted into energy-rich biogas.
Cleaning In Place (CIP)
After anaerobic treatment, the UF membrane unit separates the clean permeate from the biomass.
If required, several polishing techniques are available to further treat the suspended solids free effluent for reuse or recovery of nutrients, while the low COD permeate is often clean enough for direct discharge to sewer.
Biomass is returned to the bioreactor, while a small amount of biomass is removed from the system and discharged after dewatering.
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Memthane®; Features
Treat high-strength effluent previously considered untreatable • High concentrated streams : COD 15,000 – 250,000 ppm
• Superb effluent quality
• Create product for nutrient recovery (N+P)
Maximize renewable green energy production • Generates biogas from wastewater
• Minimizes carbon footprint and water footprint
Remove COD efficiency: > 98% • Avoids costly aerobic post treatment
• Generates more biogas
Reduced OPEX • Reduces disposal costs while generating biogas
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Anaerobic MBR; full scale case Dairy wastewater
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9 tCOD/day
COD loading and COD removal over 2.5 years 3 day moving average
Memthane®; Track record
Proven Innovation 9 full-scale Memthane® plants
• 4 years of full-scale industrial operation
• 14 pilot plant tests
Implemented in: • Dairy industries
• Bio-ethanol plant; thin stillage
• Cellulosic Bio-ethanol; condensate
• Biodiesel plant
• Food processing
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Ethanol distillery; Case study
Production Capacity: 10,000 m3 Ethanol per year
Bases: Corn
Flow: 700 m3/day / COD: 48 ton/day
TKN: 720 ppm / t-P: 820 ppm
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Biogas Boiler
DAF
Stillage Centrate
BT
Dilution Effluent
DAF Float
BIOBED
Post Treatment
Post Treatment
Biogas
BT
AnMBR sludge stream
MEMTHANE
Ethanol distillery- Case study
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Biogas
Memthane®
Water Re-Use
Evaporator
Thin Stillage
Electricity CHP
Back set water
N - removal Ammonia Stripping
P- removal Struvite & Anitamox
Memthane Development Works…
Water Re-Use RO Treatment
Boiler Feed Water Cooling Water & Other
Ammonia for Re-use
Fertilizer
Decanter
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Full scale design Bio-ethanol
Memthane® treating thin stillage of 45 ton COD/d
COD removal efficiency > 98 - 99% • Gross caloric value >5.4 MW
Electrical balance • Production 2.2 MWe
• Consumption Memthane® 0.3 MWe
Post treatment options • Struvite precipation
• Water Re-use
• Ammonia re-use
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Observations and Conclusions
Biobed® Advanced reactor • Reduced investment and operating costs
• Stable and reliable operation
• 25 full scales
Biobed® SMART • Substantial reduction in operating costs
• More stable operation
• Especially as retrofit to existing plants
Memthane® AnMBR • Cost effective solution for concentrated wastewaters
• Crystal clear effluents
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Biothane: Establishing growth through innovation Thanks for your attention For further information or questions Please contact: Jan Pereboom; Marketing Manager at Biothane [email protected] or visit our booth: Hall 5 F124
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