acqueau workshop helsinki 2015_chemical solutions session_antonia morales_cefic
TRANSCRIPT
Chemical Industry working for Efficiency:new approaches to improve water management
Acqueau Workshop: Industrial Waste Water Treatment
Helsinki, March 12th 2015
Antonia Morales PerezChristina Juengfer - Dechema
Presenting Cefic
Funded in 1972, Cefic is the voice of the European chemical industry.Represents 29.000 large, medium and small chemical companies, with640 members and affiliates. The network is complemented bypartnerships with other industry associations representing various sectorsin the value chain.
1.2 million direct jobs
559 billion sales in 2012,≈ 20% worldwide sales
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Chemical Industry,on the right track
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Innovation
Sustainability Resource Efficiency
SusChem ETP andthe National Technology Platforms (NTPs)
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SusChem:European Technology Platform for Sustainable Chemistry
Who we are :SusChem - the European technology and innovation platform for sustainable chemistry bringing together industry, academia and society
SusChem Mission : To initiate and inspire European chemical and biochemical innovation to respond effectively to society’s challenges
SusChem Vision :To achieve a competitive and innovative Europe where chemistry provides sustainable solutions for future generations
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E4WATER - CASE STUDY OVERVIEW
The research leading to these results has received funding
from the European Union Seventh Framework Programme
(FP7/2007-2013) under grant agreement n° 280756.
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E4WATER CASE STUDIES (CS)
CS4: Italy/ Czech Republic:
in-process water loop closure,
new technology trains
CS1: Netherlands:
Mild desalination,
alternative water
sources
CS2: Belgium:
multi-company
site, Identification
of Synergies
CS5: France: Integrated
water management at a
petrochemical site
CS3: Spain: water loop closure, ensure
process continuation
CS6: Denmark: Industrial
Symbiosis, new
technologies for an
integrated water
management systemWater use ↓
Waste water production ↓
Energy use ↓
Economical efficiency ↑
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Mild desalination of water streams for optimum reuse in
industry or agriculture at affordable costs - Lead by Dow
Terneuzen, NetherlandsSite: Dow Terneuzen, in the south
of the Netherlands, close to the
community
Production: plastics/ chemicals
Situation:
-Scarce fresh water region
-Relative diluted water streams with
different flows
Objectives/Challenges:
-use more streams in the region
(rain water, agriculture, municipal
and industrial waste water)
-find the possibility to collect and
desalinate all streams for low cost
water management.
CASE STUDY 1 - OVERVIEW
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Selected raw water streams: collected Rain /Surface Water, Treated Process Waste Water,
Blowdown from process cooling towers
demo facility:
Robust pretreatment: Coagulation/Flocculation, Ultrafiltration
mild desalination: 2 parallel trains: (1) Nanofiltration, (2) Electrodialysis Reversal
(EDR)
First results:
rain/surface water + treated ww tolerate a fairly modest pretreatment
Cooling tower blow down water apparently is more challenging, due to the nature of the
constituents present in the water
CASE STUDY 1 – FIRST RESULTS AND OUTLOOK
OUTLOOK: scale up mild
desalination units to produce
water from various sources
at affordable costs
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Production: chlorine (Cl2), sodium hydroxyde
(NaOH), Hydrogen (H2) und sodium
hypochlorite (NaOCl).
Enhance the water reuse by global management and synergy
identification on a multi-company site - Lead by SolVic, Belgium
Situation:
-Pressure on fresh water resources.
-Regulatory demands.
-Treatment of high inorganic loaded wastewater,
-Recycle for high quality use,
-Facilitate use of reclaimed water
Objectives:
-Managing the total quantity of waste water
-Upgrade low quality water ( effluents, rain- & freatic water)
streams for re-use
-industrial experimental garden: permanent modular
industrial scale demo unit for water/wastewater or effluent
re-use and for testing new technologies and new materials
Site: Solvic Lillo, Port of Antwerp – Chemical
Cluster
„Multi Company Site“
CASE STUDY 2 - OVERVIEW
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Industrial experimental garden
Different water sources on site
Stage 1 DEMO + Stage 2 DEMO: RO
based desalination installation that aims to
produce high quality process water. Served
as basis for a full scale unit
Stage 3 DEMO: external ww with high salt
concentration for the chlor-alkali process.
Pilot: “Mobile Kit” for recycling in the process
of Solvic. Can be transported and used on
other multi-company site to test the
possibility of recycling waste water in the
same process
Industrial experimental garden: will
provide a platform for demo scale testing of
technologies that allow to improve water and
salt reuse in chemical industry; incorporate
industrial symbiosis
CASE STUDY 2 – FIRST RESULTS AND OUTLOOK
Outlook: continuing with working on the
water management concept to come
close to zero salt waste and zero liquid
discharge.
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Ensure process continuation by closing the water loop and
minimizing fresh water use - Lead by SolVin, Spain
Site: North of Spain, region of Barcelona
Production: PVC, Vinyl products
Situation:
- Waste water has complex organic
load, high flow
- Fresh water limitations
- Emissions taxes
- Plant capacity increase
Objectives:
-Water-loop closure for PVC process up to
90%
-Management of the concentrates
-Pre-basic design
CASE STUDY 3 - OVERVIEW
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MBR Pilot Plantis running: a submerged hollow fibre membrane is used for the UF (good
experience in lab tests). Aim: the treated water is meant to reach the quality specifications for
recycling back to the original process after a desalination step by RO recycling back
Results:
After one month of treatment: an almost acclimatization of biosludge was achieved, with
PVA removals higher than 98%
After six months of treatment: COD and BOD removals are in the range of 80-90% and
>95%, respectively.
In parallel: lab-scale MBR. Aim: to check the replication potential of the treatment route by
testing different PVC effluents qualities applying the same commercial membrane quality.
CASE STUDY 3 – FIRST RESULTS AND OUTLOOK
Outlook:
Solvin will keep
working on its
water
management
concept on
different
production sites
throughout
Europe.
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Enhance in-process water loop closure by integrating biocidal with
wastewater treatment technologies - Lead by PGB N.V., Italy
Site: different production sites in Italy
Production: liquid consumer goods products in
Fabric Care, Home Care and Beauty Care
Situation: high concentrated wash water
generated during cleaning and sanitisation
(COD 20,00 – 50,00 mg/l)
Aim:
-Cleaning and Sanitization water from liquid consumer
goods products in Fabric Care, Home Care and Beauty
Care
-Progress beyond state of the art: combine „waste water
treatment“ technology and „pasteurization/sterilisation“
technology to recycle high concentrated wash water
generated during cleaning and sanitisation
CASE STUDY 4 - OVERVIEW
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Tests on 2 innovation pathways
1: segregation and separation technologies (e.g.
sensors, membranes, evaporators etc.)
2: use of traditional wastewater treatment
technology for this kind of water
several products were tested to see how the
technologies interact with different types of surfactants
which can be present in household chemical products :
anionic, cationic, non-ionic and amphoteric surfactants.
Based on test results: a treatment system has been
defined, combining Nano Filtration Tubular
membranes with MBR.
This treatment system will reduce the overall cost of
wash water handling and will allow treated water to be
recycled into the process as cooling tower feed water.Plan of the 6 ton/day membrane unit for the
Procter & Gamble E4Water pilot site
Outlook:
final lab testing to finalize the design criteria for the Tubular membranes
Test of treatment system (Tubular Nanofiltration + MBR) in P&G plants with different types of surfactant
containing products.
lab testing with different types of technologies on the 3th innovation pathway (use of biocidal
technologies) to define the technology to be able to reuse/recycle chemicals which are inside the wash
water.
CASE STUDY 4 – FIRST RESULTS AND OUTLOOK
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Towards integrated water management system in petrochemical site
- Lead by Total Petrochemicals, France
Site: Costal region (regulatory restrictions,
increasing salinity)
Production: base chemicals and their related
polymers – polyethylene, polypropylene and
polystyrene
Situation:
- Waste water and cooling water streams with
organic and inorganic loads and very high flows
- High consumption rate for cooling and boiler
feed
Aims:
-New water management system that integrates
three major water streams:
•Plant waste water
•Water streams in cooling circuit loop
•Water blow down for the cooling circuit
- Enhanced recycling in cooling circuit
-Reduction of water abstraction > 40 %
-Compliance with limits for wastewater discharge
-Process reliability
CASE STUDY 5 - OVERVIEW
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COOLING TOWER BLOWDOWN PLANT for water
reuse purposes.
Ultrafiltration (UF): filtration flux, filtration time,
coagulant are adapted to get the right Trans
Membrane Pressure. So far, optimized parameters
are close to a filtration flux of 65 lmh and a filtration
time of 40 minutes.
Reverse Osmosis (RO) is feeded by UF. Specific
attention is paid on the permeat quality while RO
brines will have to achieve existing emission limit
values on discharge waters. So far, a concentration
rate of 4 for inorganics has been observed between
inlet UF and outlet RO
COOLING WATER CIRCUIT TREATMENT:
sand filter: ensure a “downstream protection” of
total suspended solids of 10 mg/L
1st disinfection: UV pilot: tested UV doses showed
effect under Legionella concentrations: stabilization at
low dose and decrease at high dose.
2nd disinfection: ozonation: showed effective
controlling of microbial flora in the cooling tower pilot.
EXTENDED WASTEWATER TREATMENT PLANT:
•biofilter: showed efficiencies consistent with
expectations (85% of BOD removal, 50% of COD
removal)
•ozonation: still operated in batch sequences at
doses lower than 15 mg/L. A last O3 campaign is
foreseen after the membranes are stabilized.
•UF/ RO: as follow
CASE STUDY 5 – FIRST RESULTS AND
OUTLOOK
Results:
3 treatment lines for recycling
water
Outlook.
determine the optimal treatment pathway on a
petrochemical plant for achieving the objective at
least a 40% reuse rate
Lab works for identified complex streams
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Bioextraction technology in a symbiotic industrial wastewater
treatment concept creating added value - Lead by Cluster Biofuels
Denmark
Objectives:
deliver an industrial wastewater treatment system, based on
microalgae, where the maximum removal of nutrients equals
maximum added value:
Site: Industrial Symbiosis Kalundborg
Situation: industrial ecosystem, where the residual by-
product of one enterprise is used as a resource by another
enterprise, in a closed cycle. Local collaboration: public and
private enterprises buy and sell residual products, resulting in
mutual economic and environmental benefits.
CASE STUDY 6 - OVERVIEW
-Maximize nutrient removal from waste streams via microalgae growth
-Define the best method for separation of the resulting biomass from the purified water
-Characterize the biomass components to identify added value targets
-Evaluate extraction technologies for the different targets
-Access and evaluate the overall bio-extraction technology in an industrial symbiosis wastewater treatment concept
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ACTIVITIES
-screening of technologies for pre- and post-treatment activities.
-Selection of suitable ww for microalgae production
-Suggestion of best microalgae candidates for ww treatment based
on a high-throughput screening method in microtiterplates coupled to
a fluorescence plate reader.
-completion and official opening of the RTD microalgae facility at the
WWTP in Kalundborg (October 8th 2013)
FIRST INITIAL TESTS ON BIOMASS PRODUCTION AND
NUTRIENT REMOVAL
- on one of two screened process water stream
-in a large-scale photobioreactor (4.000 liter)
-initial tests on pre-treatment of the process water (mechanical
sterilization) and post-treatment of the generated algae biomass
(dewatering/harvesting)
-Analytical protocols established for biochemical composition of
microalgae biomass and for the microplate screening procedure
validated to mesoscale.
-Chemical analysis on the process water before and after treatment
and on the generated biomass, in order to identify the potential in
nutrient removal and biomass quality generated as a result of a low
nutrient based process water growth media, a freshwater microalgae
strain and winter process conditions (low light and temperatures).
CASE STUDY 6 – FIRST RESULTS
AND OUTLOOK
OUTLOOK:
-Large-scale trials in multiple batch
reactors and combined continuous
configuration, on pre-gasified and
mechanical sterilized high nutrient
industrial process water.
-Process optimization and
evaluation on bioextraction concept
combined with an industrial
symbiosis approach.
-Potentials from added value
evaluated with reference to
downstream processing in a
suggested biorefinery concept
-Commercialisation potentials of the
Kalundborg concept - Business
Case
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www.e4water.eu www.cefic.org www.suschem.org