PROCESS FACT SHEETS DCWASA will consider only proven technologies for further evaluation. Proven is defined as operating at least at one facility (>20-30 MGD) with municipal sludge for at least one full year. However, if the technology has a strong potential to meet the proven criteria it may be considered for processing a portion of the solids, if cost effectiveness can be established. ACID GAS PHASE DIGESTION I. Description The Acid Gas Process consists of a highly loaded “acid phase” digester followed by a more lightly loaded “methane phase” digester. The first phase provides hydrolysis and acidification during the 1 – 2 day detention time; while the second stage maximizes gas production and usually has a detention time of about 10 days. This process can result in Class A biosolids only if one phase is operated in thermophilic mode. II. Technology Classification: Established III. Installations: Multiple facilities exist across North America. Note: Acid Gas Phase Digestion typically uses conventional anaerobic digesters. The methanogenic bacteria used are difficult to grow and sensitive to overloads. Two-phase digestion is resilient to changes in feed volume and composition because the acidogenic bacteria are hardy and do well under extreme loading conditions. It is also claimed that the technology minimizes or eliminates foaming problems. Acid Gas Digestion is undergoing Phase II screening as a digestion alternative for biosolids management at Blue Plains. Acid Gas Phase Digestion -1- AUTOTHERMAL THERMOPHILIC ANAEROBIC DIGESTION - TEMPERATURE PHASED ANAEROBIC DIGESTION (ATAD-TPAD) I. Description ATAD-TPAD is a dual digestion system consisting of aerobic and anaerobic digestion. mesophilic temperatures. The process also produces methane gas which can be used for process heating. The first step is a short residence time Autothermal Thermophilic Aerobic Digestion (ATAD). ATAD achieves Class A pasteurization in small aerobic digesters operating at thermophilic temperatures, with 1-2 day detention time. Autothermal heating, pre-conditioning, and Class A pasteurization occur in this step. The second step is Temperature Phased Anaerobic Digestion (TPAD), where thorough volatile solids destruction and stabilization occur. The pasteurized, pre-conditioned biosolids are digested in a series of three anaerobic phases descending in temperature from thermophilic to high mesophilic to low II. Technology Classification: Established III. Installations: Multiple facilities exist across North America. Note: ATAD-TPAD is currently operating in Barrie, Ontario (Canada), Henderson, NC (USA), and Tacoma, WA (USA). Its advantages include minimum heating requirements with most of the heat required in the TPAD stage is obtained from the auto thermal stage. Some challenges presented by ATAD-TPAD include installation and maintenance of the Oxygen generation system. While air can be used in the ATAD stage, it has a markedly lower efficiency than oxygen. ATAD-TPAD is undergoing Phase II screening as a digestion alternative for biosolids management at Blue Plains. ATAD-TPAD -2- BELT FILTER PRESS DEWATERING I. Description The belt filter press process consists of a multiple, woven belt, gravity and compression unit. Belt Filter Press sizes are measured by belt width in meters with standard units ranging from .5 to 3.5 meters. Hydraulic loading can vary from 25 to 100 gpm per meter of belt width and dry solids loading from 500 to 1000 lbs/hr per meter of belt width. Solids capture is typically 8598% and resulting total solids (TS) of the cake have concentrations of 18-32%. Conditioned biosolids are applied to belts that filter solids and drain released water from the mixture. Gravity and pressing forces are applied to the biosolids as the belts transfer the mass through the press. The process, which has a dry solids output of 18-32% may be solids limited for feed streams that are greater than 4-6% TS. II. Technology Classification: Established III. Installations: Multiple facilities exist across North America. Note: Belt Filter Presses are mostly used for post-digestion dewatering. They typically consume less energy and generate less odorous cake than centrifuges, which may be required for options that produce Class A biosolids product that is not heat dried.. Belt Filter Press dewatering is undergoing Phase II screening as a dewatering alternative for biosolids management at Blue Plains. Belt Filter Press -3- CAMBI I. Description The process subjects thickened primary and secondary sludge to high pressures and temperatures. The treatment process, as depicted in the next figure, can be summarized as follows (adapted from Stowa fact sheets). The sludge is pre-dewatered to around 15% to 20% dry solids (DS) content. The sludge is then pre-heated in the 1st reactor (Pulping Tank 1), as it is continuously fed to the reactor. It is batch fed into the 2nd reactor (Pulping Tank 2), to which steam is added at 12 bar in order to achieve temperatures of 150 to 160°C and pressures of about 8 to 9 bar. Before discharging from the 2nd reactor the pressure is decreased to approximately 2 bar; the released steam is recirculated to the 1st reactor for pre-heating of the incoming sludge. The sludge cools down in the 3rd reactor to about 100°C. The hydrolyzed sludge is cooled down further to 35°C by tube-intube heat exchangers for the production of hot water, diluted and subsequently fed to II. the digester. Typical retention times in the digester range from 10 to 12 days, however, in Dublin plant the SRT is 15 days. How the Cambi fit in the overall treatment scheme 12-14% The Cambi Components • • • Achieve up to 62% VSR Reduce digester volume by ~ 50% Dewatered cake about ~33-40%, centrifugation Technology Classification: Innovative Cambi -4- III. Installations: Treatment plants that operate Cambi facilities include:- Location Brisbane Bydoszcz Niigata Hias Sarsborg Lillehammer (NOR) (1996) Chertsey (GB) (1999) Næstved (DEN) (2000) Frederica (DEN) Aberdeen (Scotland) Dublin-Ringsend (Ireland) Solids Production, dtpy 15,000 8,000 1,200 3,600 4,000 4,600 8,000 1,600 8,000 16,500 36,000 Notes from Dublin plant visit: 1. Cambi is a sophisticated process to operate, and requires well trained operators. The Dublin Cambi process seems to be currently operated mainly by Black & Veatch engineers 2. The technology may raise safety and cost concerns from high pressure operation. 3. Further investigation is required in order to address the increased ammonia concentration in the digester. 4. Cambi components need to be enclosed in order to treat odor emissions from the tanks. 5. The recycled centrate should be evaluated for its nutrient, hydrocarbon, and soluble solids quality. While the facility is supposed to produce >30% solids, the dark appearance of the centrate indicated low solids recovery. 6. Fecal Coliform reactivation regrowth should be investigated if the biosolids produced are to be dewatered via centrifugation. CAMBI process is undergoing Phase II screening as a pre-treatment alternative for biosolids management at Blue Plains. Cambi -5- CENTRIFUGE DEWATERING I. Description Centrifugal thickening and dewatering is a high speed process that uses the force from rapid rotation of a cylindrical bowl to separate wastewater solids from liquid (U.S. EPA, 1987). High speed rotating equipment develop large gravitational forces separating liquids from solids. Centrifuge thickeners have been placed before digesters in order to reduce tank volume needed for digestion. Centrifuges are also used post digestion to dewater sludge before hauling, as at Blue Plains. Centrifuges operate as continuous feed units which remove solids by a scroll conveyor and discharge liquid over the weir. The bowl is conical-shaped which helps lift solids out of the liquid allowing them to dry on an inclined surface before being discharged (Kemp, 1997). II. Typical centrifuge capacities range from 200-300 gpm to 850 gpm. The output total solid content on anaerobically digested sludge is typically 2834%. Solids capture is typically 88-95% with polymer applications of 16 lb/ton-dry solids. Technology Classification: Established III. Installations: Multiple facilities exist across North America. Note: Centrifuge units are undergoing Phase II screening as thickening and dewatering alternatives for biosolids management at Blue Plains. Centrifuge -6- COMPOSTING I. Description Composting is a system that uses microbial activity to degrade raw organic materials, such as yard trimmings and sludge solids, so that the end-product is relatively stable, reduced in quantity (in comparison to the initial amount), and free from offensive odors. It is typically employed post dewatering in order to obtain the finished compost material for land application. Class A biosolids can be generated based upon times and temperatures in the process. Initially, high microbial activity and heat production cause temperatures within the compostable material to rise rapidly into the thermophilic range (50oC and higher). This temperature range is maintained by periodic turning or the use of controlled air flow. After the rapidly degradable components are consumed, temperatures gradually fall II. during the "curing" stage maintaining a temperature of 131oF for 3 to 15 days. Moisture, bulking material, and aeration control are required and multiple handling of the material is typical. Space is usually an issue. Technology Classification: Established III. Installations: Multiple facilities exist across North America. Note: Due to odor management issues, the composting facility that was previously operated onsite at Blue Plains was taken offline. Composting is not undergoing Phase II screening as a mainstream alternative for biosolids management at Blue Plains. However, composting, as a peak shaving option, will be considered. Composting -7- THERMAL DRYING I. Description Thermal drying is employed after digestion and dewatering to reduce the moisture content of sludge. It uses heat to reduce the volume and mass of dewatered solids by evaporating water from biosolids, creating a Class A product. It typically increases the solids content from between 18-30% to between 90-96%. The high temperatures applied can also help meet US EPA Part 503 requirements for pathogen destruction and vector attraction reduction. Resulting Class A biosolids can have the consistency of fine granules, flakes, small pellets or larger fragments depending on the type of thermal drying system used, characteristics of biosolids processed and the use intended for the product. with wet biosolids. The high temperatures transferred to the solids evaporate the water. Examples of direct dryers are rotary drum, flash and belt dryers. With indirect heat dryers, solid metal walls separate wet biosolids from the heattransferring medium such as steam, hot water or oil. Biosolids temperatures are raised by contact with hot metal surfaces and the water subsequently evaporated. Indirect dryers include vertical tray, paddle, disc, and indirect-type fluidized bed dryers. Thermal drying systems are typically referred to in two primary categories; direct and indirect heat dryers. In direct dryers hot air or gas produced by oil or gas-fired furnaces flows through the drying vessel and comes into direct contact II. Technology Classification: Established III. Installations: Multiple facilities exist across North America. Note: Thermal drying ensures high-value, marketable products and provides a diversification option for sustainable biosolids management. Thermal drying is undergoing Phase II screening as an alternative for biosolids management at Blue Plains. Enzyme Hydrolysis -8- ENZYMIC HYDROLYSIS I. Description Enzymic Hydrolysis (EH) is a form of twophase digestion that uses enzymes produced by bacteria to hydrolyze organic matter. During the hydrolysis step large complex molecules such as carbohydrates, proteins, and fats are converted to soluble simpler molecules which may be assimilated by bacteria. Enzyme Hydrolysis uses thickened sludge as a feed material typically and is followed by mesophilic anaerobic digestion. In this biological process extracellular enzymes serve as catalysts to destroy cell components prior to digestion. This enhances gas productionr, reduces HRT in the digester, and typically provides for better dewatering. In the methanogenesis step, obligate anaerobes convert the hydrolyzed molecules to methane gas. A typical enhanced EH design involves 2day retention at 42oC resulting in 99.9% E.Coli reduction. In order to obtain a Class A product, an enhanced EH design consisting of 3 tanks operated at 55oC optimizes VS destruction. II. Technology Classification: Innovative III. Installations: Treatment plants that operate enhanced Enzyme Hydrolysis facilities include:- Location Blackburn, UK Solids Production, dtpy 13,500 Note: Enzymic Hydrolysis is undergoing Phase II screening as a pre-treatment alternative for biosolids management at Blue Plains. This being considered as a subset of acid gas digestion. Enzyme Hydrolysis -9- GASIFICATION I. Description The technology reduces the volume of dried biosolids producing gas that can be used to generate electricity. The gasification process converts sludge or biosolids into a combustible gas, referred to as synthesis gas, or “syngas,” which can be recovered. While incineration fully converts the input waste into energy and ash, gasification heats the material under controlled conditions, deliberately limiting the conversion so that combustion does not take place directly. Syngas can be used as a fuel to generate electricity and heat. The fuel value of Syngas is not typically as high as that of digester gas, perhaps 60% of digester gas energy values. The gasification process takes place in two steps: pyrolysis and partial combustion. During pyrolysis, biosolids are degraded in the absence of oxygen at 1400-1650oF resulting in the formation of gas and a black, carbon-rich substance called “char.” Gasification Image The Balingen Plant, Germany In the second reaction, the char is gasified by partial combustion in the presence of oxygen or air to produce the syngas. The gas will require purification prior to beneficial reuse. Due to the concentrating effect of the constituents in the original biosolids, the remaining char is usually applied in a landfill. Kopf Umwelt- und Energietechnik GmbH gasification technology Gasification - 10 - II. Technology Classification: Embryonic III. Installations: Treatment plants that operate Gasification facilities include:- Location Philadelphia Water Department, PA Balingen Sewage Works, Germany Solids Production, dtpy 3, 650 1,460 Notes: The pilot-plant installation in Balingen shows the following performance: Cold gas efficiency between 65 and 70 % depending on the degree of drying which means that about two thirds of the energy contained in the sewage sludge was becoming combustible gas. The gas engine produces about 70 kW of electrical energy, of which about 15 kW are required for gasification. The rest is available for the sewage works to cover its energy demand. The thermal output of the co-generation (about 140 kW) is used to heat the digester towers. The surplus of gas which cannot be used in the co-generation is disposed of in a post combustion chamber. The mineral granule amounts to 85 kg/h, it is used in an asphalt mixing plant. The key component of the KOPF (Kopf Umwelt- und Energietechnik GmbH) gasification process is the gasification reactor, where combustible gas is produced from dried sewage sludge. This occurs in a stationary fluidised bed by sub-stoichiometric combustion at temperatures up to 900°C. In the raw gas quench, the gas is cooled down and subsequently reprocessed by filtering and drying. In a block type heat-power system, the gas is used to produce electricity and heat. After a retention time of 30 minutes, the sewage sludge is reduced to an inert granule. As an embryonic process, Gasification does not demonstrate proven capability to operate at Blue Plains’ scale (>20 MGD). Gasification is not undergoing Phase II screening as an alternative for biosolids management at Blue Plains. Gasification - 11 - INCINERATION Description I. Incineration is the burning of dewatered sludge at temperatures ranging from 12001700o F. A minimum of 25% feed solids is usually provided to reduce supplemental fuel. There are two types of incinerators in general use: the multi-hearth and fluidized bed. The latter type is typically installed today in retrofit applications. In addition to supplemental fuel, additional combustion air is normally required; air pollution control measures are now a significant cost component. Biosolids volume reduction is in the range of 75-85% with options available for reuse of the ash. II. Technology Classification: Established III. Installations: Multiple facilities exist across North America. However, no new large installations have been built in recent years. Note: While incineration provides energy recovery and low quantity ash production advantages, the regulatory approval process for timely permit review and approval makes this process non-viable for implementation at Blue Plains. Incineration is not undergoing Phase II screening as an alternative for biosolids management at Blue Plains. Incineration - 12 - LIME STABILIZATION I. Description During lime stabilization involves addition of lime to biosolids in order to raise the pH to levels unfavorable for pathogen growth. The heat produced by the reaction of the lime with the water in the biosolids raises the pH and temperature of the biosolids sufficiently to comply with U.S. EPA’s 40 CFR Part 503 regulations for pathogen destruction for both Class A and Class B biosolids. Generally, lime stabilization meets the Class B requirements when the pH of the sludge-lime mixture is at 12 or above after 2 hours of contact and subsequently maintained above pH 11.5 for another 22 hours without further lime addition. Class A requirements can be achieved when the pH of the mixture is maintained at or above 12 for at least 72 hours, with a temperature of 52oC maintained for at least 12 hours during this time. Class A biosolids requirements can also be satisfied by combining the Class B requirements with elevated temperatures (70oC for 30 minutes) or other EPA-approved time/temperature processes. Producing a Class A product generally requires a significantly larger lime addition than is required for Class B biosolids. The process is approved by EPA as satisfying one of the five Processes to Significantly Reduce Pathogens (PSRP) listed in the Part 503 regulations. significantly enhance pathogen destruction. Other materials such as hydrated lime can also be used. In general, lime stabilization is a nonproprietary process, although several patented processes are available. Lime stabilization has been demonstrated to reduce total Coliform, fecal Coliform, and fecal streptococci by more than 99.9 percent. Exceptional Quality (EQ) biosolids can be produced if Class A pathogen reduction, vector attraction reduction, and metal concentration requirements are met. The process converts sewage sludge into a stable product, improves the density and physical handling characteristics of the biosolids and offers a cost-effective, flexible, and environmentally protective alternative that promotes beneficial reuse. The lime stabilized biosolids provide a rich source of essential fertilizer to farmland, improve acidic soils, and are excellent for land reclamation and as soil substitute for landfill cover or as soil conditioner. Quicklime (calcium oxide) is commonly used because it has a high heat of hydrolysis and can II. Technology Classification: Established III. Installations: Multiple facilities exist across North America. Note: Lime Stabilization is Blue Plains’ current sludge treatment process. Upgraded, it can be used to process peak loads in excess of the max 30-day design load of up to 200 dtpd. Lime stabilization is undergoing Phase II screening for biosolids management at Blue Plains, as a peak shaving option. Class A lime stabilization is not being considered as a mainstream option as the high pH product may limit its suitability for land application. Lime Stabilization - 13 - MESOPHILIC ANAEROBIC DIGESTION I. Description Mesophilic Anaerobic digestion is a stabilization process that reduces the quantity of sludge, its pathogens, and odor in the absence of oxygen. The organic portion of sludge is biologically degraded to produce methane gas. The methane is generally burnt on site for heating or to produce electricity on a small scale. This type of digestion can be used in combination with other technologies to produce either a Class A or Class B biosolids. Anaerobic digesters will require an energy input to retain the material at elevated temperatures (between 20 and 40°C - the mesophilic range) in order to speed digestion. Some of the energy available from the methane generated (typically 2040% of the total energy produced) can be recycled for this purpose. Residence times depend on the amount of sludge to be processed and vary between 15 – 30 days. II. Technology Classification: Established III. Installations: Multiple facilities exist across North America. Note: Mesophilic Anaerobic Digestion can be combined with pre- or post- treatment processes in order to generate reduced quantities of biosolids. Mesophilic Anaerobic Digestion is undergoing Phase II screening for biosolids management at Blue Plains. Mesophilic Anaerobic Digestion - 14 - PASTEURIZATION I. Description Pasteurization is a two-stage process that is pre-treatment process that utilizes sludge heat exchangers and small biopasteurization tanks, followed by anaerobic digestion. In the first stage of the process, a BioPasteurTM system heats the sludge to 70oC for a minimum of one hour in order to provide for pathogen destruction and meet EPA’s Class A pathogen reduction requirements. can be treated to a level that will allow for various uses. Pasteurization not only reduces the quantity of sludge and its pathogens, but also reduces odor as well. This type of digestion can be used ahead of a number of other technologies and depending on the operation and accompanying process can generate either a Class A or Class B biosolids. In the second stage, anaerobic digestion systems provide the volatile solids reduction at either thermophilic or mesophilic operating temperatures. Three batch pasteurization reactors are operated in a staggered configuration to ensure continuous discharge of sludge into anaerobic digesters. Gas is produced and II. Technology Classification: Innovative III. Installations: Treatment plants that operate Pasteurization facilities include:Location Alexandria Sanitation Authority, VA WWTF City of Carmel, IN WWTP Charlottetown WWTP, Prince Edward Island, Canada Plant size (MGD) 50 MGD 12 MGD 6 MGD Note: Pasteurization is not undergoing Phase II screening as an alternative for biosolids management at Blue Plains. Pasteurization - 15 - TEMPERATURE PHASED ANAEROBIC DIGESTION (TPAD) Description I. Thermophilic digestion is often coupled with mesophilic digestion in a temperaturephased anaerobic digestion (TPAD) system. Studies have reported that TPAD systems may produce more biogas, increase volatile solids destruction, and inactivate pathogenic microorganisms more completely than comparable conventional mesophilic digestion systems. In thermophilic digestion the reaction rate and pathogen disinfection are increased by raising the temperature to 122-135 ºF (50 to 57ºC) to support thermophilic bacteria. TPAD can have several variations: Thermophilic digesters in series followed by mesophilic Mesophilic Thermophilic Mesophilic Thermophilic Mesophilic (TPAD) Since thermophilic digestion is typically not a batch process, it is not recognized as a Class A process. The process can be run in batch mode to meet time-temperature relationship established by EPA. II. Technology Classification: Established III. Installations: Multiple facilities exist across North America. Note: TPAD is undergoing Phase II screening as a digestion alternative for biosolids management at Blue Plains. TPAD - 16 - VITRIFICATION/ GLASSPACK® PROCESS I. Description The technology converts sludge into glass aggregates, which is inert material that can be used in construction material such as bricks, asphalt paving, shingles, etc. The sludge goes through a closed loop of drying and melting processes. The process eliminates the need to co-fire fuel to achieve Vitrification. glass flows out of Zone 2 into the quench tank, where it is cooled to form the glass aggregate product. In Zone 3, gas cooling occurs. The exhaust gas blends with re-circulated gas (375oF), thereby reducing the temperature of the gas mixture to 1,400oF. Melter Zones Only natural gas is used heat the melter to the required temperature before the sludge is introduced. The heat recovered from the vitrification loop provides the required heat to dry the sludge. According to Minergy, the melter is comprised of a three-zone operation with separate, but interconnected chambers. In Zone 1, melting and combustion occurs. Synthetic combustion air (mixture of 90% pure oxygen and recovered exhaust gas) is introduced tangentially to the combustion chamber and is mixed with the incoming granulate at a temperature between 2,400oF and 3,000oF. The organic fraction of the granulate is combusted (fuel source), while the inorganic fraction of the solids melt to form a pool of molten glass. In Zone 2, the separation of the molten glass and exhaust gas occurs. The molten II. Technology Classification: Innovative III. Installations: Location Demonstration unit in Winneconne, WI North Shore Sanitary District, IL Solids Production, dtpy 4,380 11,680 Note: As an embryonic process, Vitrification does not demonstrate proven capability to operate at Blue Plains’ scale (>20 MGD). Vitrification is not undergoing Phase II screening as an alternative for biosolids management at Blue Plains. Vitrification -17- SLURRYCARBTM I. Description The SlurryCarb process is based on the pyrolysis concept and involves exposing the biosolids to elevated temperature (450-600oF ) and pressure (800-1,800 psig)for a defined period of time, followed by cooling, depressurization, dewatering and, if desired, drying and pelletization of the product solids. Current practice is to operate at 450oF and 1,200-1,500 psig, which is lower pressure and temperature than typical pyrolysis. The effect of elevated temperature and pressure on biosolids is to partially solubilize the solids through breakdown of the cell walls, breaking molecular bonds and, in this case, releasing CO2 gas via the carbonization process. The remaining solids (char) can be readily dewatered using a high-speed centrifuge, allegedly to about 50-55% solids chemical conditioning. For ease of transportation and increased fuel value, the product can be further dried and, if needed, pelletized, and used as a substitute for coal in power generation plants. II. Mitsubishi Plant The Rialto Facility (under construction) Technology Classification: Embryonic III. Installations: Treatment plant under construction with SlurryCarb facilities:Location Rialto Regional Biosolids Processing Facility- operational end of 2008; Rialto, California Solids Production, wtpd 683 wtpd Notes: There are no SlurryCarb facilities that process municipal sludge. The Rialto facility is under construction and is expected to be in operation at the end of 2008. Although HDR provided due diligence to guarantee performance of the process, reliability and actual performance remains to be seen. SlurryCarbTM is not undergoing Phase II screening as an alternative for biosolids management at Blue Plains. SlurryCarbTM -18-
© Copyright 2026 Paperzz