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Assessment of Technology Advancements for Future Energy Reduction
Water Environment Research Foundation635 Slaters Lane, Suite G-110 n Alexandria, VA 22314-1177
Phone: 571-384-2100 n Fax: 703-299-0742 n Email: [email protected]
WERF Stock No. ENER7C13b
December 2015
Assessment of Technology Advancementsfor Future Energy Reduction
Energy
Co-published by
IWA PublishingAlliance House, 12 Caxton StreetLondon SW1H 0QSUnited KingdomPhone: +44 (0)20 7654 5500Fax: +44 (0)20 7654 5555Email: [email protected]: www.iwapublishing.comIWAP ISBN: 978-1-78040-803-3
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ENER7C13b
ASSESSMENT OF
TECHNOLOGY ADVANCEMENTS
FOR FUTURE ENERGY REDUCTION
by:
Nancy Andrews, P.E. John Willis, P.E., BCEE
Chris Muller, P.E. Brown and Caldwell
2015
ii
The Water Environment Research Foundation, a not-for-profit organization, funds and manages water quality
research for its subscribers through a diverse public-private partnership between municipal utilities, corporations,
academia, industry, and the federal government. WERF subscribers include municipal and regional water and water
resource recovery facilities, industrial corporations, environmental engineering firms, and others that share a
commitment to cost-effective water quality solutions. WERF is dedicated to advancing science and technology
addressing water quality issues as they impact water resources, the atmosphere, the lands, and quality of life.
For more information, contact:
Water Environment Research Foundation
635 Slaters Lane, Suite G-110
Alexandria, VA 22314-1177
Tel: (571) 384-2100
Fax: (703) 299-0742
www.werf.org
This report was co-published by the following organization.
IWA Publishing
Alliance House, 12 Caxton Street
London SW1H 0QS, United Kingdom
Tel: +44 (0) 20 7654 5500
Fax: +44 (0) 20 7654 5555
www.iwapublishing.com
© Copyright 2015 by the Water Environment Research Foundation. All rights reserved. Permission to copy must be
obtained from the Water Environment Research Foundation.
Library of Congress Catalog Card Number: 2015948333
IWAP ISBN: 978-1-78040-803-3
This report was prepared by the organization(s) named below as an account of work sponsored by the Water
Environment Research Foundation (WERF). Neither WERF, members of WERF, the organization(s) named below,
nor any person acting on their behalf: (a) makes any warranty, express or implied, with respect to the use of any
information, apparatus, method, or process disclosed in this report or that such use may not infringe on privately
owned rights; or (b) assumes any liabilities with respect to the use of, or for damages resulting from the use of, any
information, apparatus, method, or process disclosed in this report.
Brown and Caldwell
This document was reviewed by a panel of independent experts selected by WERF. Mention of trade names or
commercial products or services does not constitute endorsement or recommendations for use. Similarly, omission
of products or trade names indicates nothing concerning WERFs or EPA's positions regarding product effectiveness
or applicability.
Assessment of Technology Advancements for Future Energy Reduction iii
About WERF
The Water Environment Research Foundation, formed in 1989, is America’s leading
independent scientific research organization dedicated to wastewater and stormwater issues.
Throughout the last 25 years, we have developed a portfolio of more than $134 million in water
quality research.
WERF is a nonprofit organization that operates with funding from subscribers and the federal
government. Our subscribers include wastewater treatment facilities, stormwater utilities, and
regulatory agencies. Equipment companies, engineers, and environmental consultants also lend
their support and expertise as subscribers. WERF takes a progressive approach to research,
stressing collaboration among teams of subscribers, environmental professionals, scientists, and
staff. All research is peer-reviewed by leading experts.
For the most current updates on WERF research, sign up to receive Laterals, our biweekly
electronic newsletter.
Learn more about the benefits of becoming a WERF subscriber by visiting www.werf.org.
iv
The authors wish to acknowledge the funding support provided by the New York State
Energy Research and Development Authority (NYSERDA) and the Water Environment
Research Foundation (WERF), and the helpful guidance of Kathleen O’Connor, P.E. and Lauren
Fillmore, Project Officers for NYSERDA and WERF, respectively. They would also like to
acknowledge Mark Philbrick with the United States Department of Energy (DOE), who assisted
in planning for the Technology Maturity Expert Panel.
The project team gratefully acknowledges the utility personnel who voluntarily
participated in this project, including the focus group participants listed below. The success of
the project is directly attributed to the dedication and enthusiasm of these utilities to share their
experiences regarding creating energy efficiency.
The authors also wish to express their appreciation to the project advisory committee for
its guidance in the design and conduct of the project.
Report Preparation Principal Investigator:
John Willis, P.E., BCEE
Brown and Caldwell
Project Team:
Nancy Andrews, P.E.
Chris Muller, P.E.
Brown and Caldwell
Rob Greenwood
Ross Strategic
Survey and Workshop Participants Damien Batstone, Ph.D.
Zhiguo Yuan, Ph.D.
The University of Queensland
Abhijeet P. Borole, Ph.D.
Oak Ridge National Laboratory
Charles Bott, Ph.D., P.E., BCEE
Hampton Roads Sanitation District
Jeanette Brown, P.E., DEE
Manhattan College
Jeff Brown, P.E., BCEE
Orange County Sanitation District
Bob Bucher
King County Department of Natural Resources and
Parks Wastewater Treatment Division
ACKNOWLEDGMENTS
Assessment of Technology Advancements for Future Energy Reduction v
Kartik Chandran, Ph.D.
Columbia University
Linda Figueroa, Ph.D. , P.E.
Colorado School of Mines
William Cooper, Ph.D.
National Science Foundation
Anthony J. Fiore
New York City Department of Environmental Protection
Jeremy Guest, Ph.D.
University of Illinois at Urbana-Champaign
Nirmal Khandan, Ph.D.
New Mexico State University
Tom Kunetz, P.E.
Metropolitan Water Reclamation District of Greater Chicago
Barry Liner, Ph.D., P.E.
Lisa McFadden
Matt Ries, M.S.
Water Environment Federation
Bruce Logan, Ph.D.
Pennsylvania State University
Nancy Love, Ph.D., P.E., BCEE
University of Michigan
James McQuarrie
Denver MWRD
Jeff Moeller, P.E.
Water Environment Research Foundation
Sudhir Murthy , Ph.D., P.E., BCEE
DC Water
John Novak, Ph.D.
Virginia Tech
Paige Novak, Ph.D., P.E.
University of Minnesota
Chul Park, Ph.D.
University of Massachusetts Amherst
Wayne Parker, Ph.D.
University of Waterloo
Mark Philbrick, Ph.D.
Department of Energy
vi
Grace Richardson, P.E.
Alexandria ReNew
Diego Rosso, Ph.D.
University of California, Irvine
Peter Schauer, P.E.
Clean Water Services
Yaniv Scherson, Ph.D.
Stanford University
Andrew Schuler, Ph.D.
University of New Mexico
Lori Stone, P.E.
LA STONE LLC
Chi-Chung Tang, Ph.D. P.E.
Sanitation Districts of Los Angeles County
Ana Pena-Tijerina, Ph.D.
City of Fort Worth
Jason Turgeon
U.S. Environmental Protection Agency, Region 1
John Willis, P.E.
Brown and Caldwell
Daniel Zitomer, Ph.D., P.E. BCEE
Marquette University
Joe Zuback, Ph.D.
Global Water Advisors, Inc.
WERF Project Steering Committee Stephen Fok, P.E.
Pacific Gas and Electric Company (PG&E)
James Horne
U.S. EPA: Sustainable Management Branch
Scott Hutchins*
U.S. Department of Energy
Maryanne E. McGowan, CPA, CEM
Duke Energy
Kathleen O’Connor, P.E.*
New York State Energy Research and Development Authority
Sudeshna Pabi, Ph.D.
Electrical Power Research Institute (EPRI)
Assessment of Technology Advancements for Future Energy Reduction vii
Claudio Ternieden
Water Environment Federation
Phil Zahreddine, MSEnvEng*
U.S. Environmental Protection Agency
*Also participated in workshop
Water Environment Research Foundation Staff Director of Research: Amit Pramanik, Ph.D., BCEEM
Senior Program Director: Lauren Fillmore, M.S.
viii
Abstract:
The wastewater industry is continuously seeking new technologies that will reduce the
need for purchased energy and improve its ability to beneficially recover resources. In addition,
within energy-positive technologies such as co-digestion that have begun to see wide levels of
deployment, there are continuing efforts to improve performance. This research reviews 18
specific technology areas to assess their current level of maturity, projected impact on sector-
wide energy use, and potential opportunities for adoption.
Based on input from researchers active in emerging technologies, mainstream shortcut
nitrogen and pyrolysis/gasification appear to be the technology areas most likely to be adopted in
the near term. These technologies are the most mature and their deployment timeline is estimated
to be relatively short. Mainstream shortcut N removal and mainstream anaerobic treatment are
expected to have the greatest impact on energy use in the wastewater sector in the near term.
Increased fundamental understanding of anaerobic communities was cited as a crucial
component of future advancement for both new technologies, and for optimization of existing
technologies such as anaerobic digestion. Refining new methods to accomplish real-time
monitoring of anaerobic community system functions was seen as a crucial part of this research.
Benefits:
Aggregates viewpoints from active academic researchers and wastewater industry
representatives.
Gauges which technologies are likely to have the greatest impact on wastewater sector
energy use.
Estimates deployment timelines for emerging technologies.
Summarizes the key areas of innovation expected to improve the energy performance and
economic viability of existing technologies and processes.
Keywords: Research, innovative treatment technologies, energy-efficient treatment, energy
generation.
ABSTRACT AND BENEFITS
Assessment of Technology Advancements for Future Energy Reduction ix
Acknowledgments.......................................................................................................................... iv Abstract and Benefits ................................................................................................................... viii List of Tables ................................................................................................................................. xi List of Figures ............................................................................................................................... xii List of Acronyms and Abbreviations ........................................................................................... xiii
Executive Summary .................................................................................................................. ES-1
1.0 Introduction .................................................................................................................... 1-1 1.1 Research Context ................................................................................................. 1-1
1.1.1 EPA Manual of Emerging Technologies for Wastewater Treatment
and In-Plant Wet Weather Flow ................................................................ 1-1 1.1.2 WERF Technology Roadmap for Sustainable Wastewater Treatment
Plants in a Carbon-Constrained World ...................................................... 1-1 1.1.3 Parallel DOE Initiative .............................................................................. 1-3
1.2 Project Overview ................................................................................................. 1-4 1.2.1 Research Objective .................................................................................... 1-4
1.2.2 Research Scope and Approach .................................................................. 1-4 1.3 Report Organization ............................................................................................. 1-4
2.0 Technology Summaries ................................................................................................. 2-1
2.1 Characterizing Technology Maturity Levels ....................................................... 2-2 2.2 Improving Energy Efficiency in Existing Treatment Facilities/Processes .......... 2-3
2.2.1 Deammonification (Mainstream Shortcut Nitrogen Removal) ................. 2-3 2.2.2 Fundamental Understanding of Anaerobic Communities ......................... 2-6
2.2.3 Improved Biogas Conditioning ................................................................. 2-8 2.2.4 Pretreatment Processes for Anaerobic Digestion .................................... 2-10 2.2.5 Aerobic Granular Sludge Systems .......................................................... 2-12
2.3 Enhanced Chemical Energy Recovery ............................................................... 2-15 2.3.1 N2O Production to Supercharge Biogas Engines (e.g., CANDO) ........... 2-15
2.3.2 Higher Hydrocarbons from Biosolids, Including HTL Methods ............ 2-17 2.3.3 Higher Hydrocarbons from Biogas or Bioliquids ................................... 2-20
2.3.4 Enhanced Methane Production from Anaerobic Digestion ..................... 2-23 2.3.5 Optimizing Co-Digestion of Food Wastes .............................................. 2-25 2.3.6 Membrane Production and Capture of Hydrogen from Wastewater ....... 2-29 2.3.7 Pyrolysis/Gasification of Biosolids ......................................................... 2-31
2.4 Technologies that Combine Efficient Treatment with Energy Recovery .......... 2-34 2.4.1 Mainstream Anaerobic Treatment ........................................................... 2-34 2.4.2 Microbial Fuel Cells ................................................................................ 2-38
2.4.3 Microbial Electrolysis Cells .................................................................... 2-41 2.4.4 Supercritical/Subcritical Water Oxidation for Sludge
Treatment and Energy ............................................................................. 2-43 2.4.5 Integration of Algal Treatment for BNR with Algal Energy Production .. 2-45
TABLE OF CONTENTS
x
2.4.6 Thermally Regenerative Ammonia-Based Batteries ............................... 2-48 2.5 Other Technologies ............................................................................................ 2-49
3.0 Technology Comparisons and Prioritization............................................................... 3-1 3.1 Technology Readiness Level ............................................................................... 3-1 3.2 Impact vs. Technology Readiness Level ............................................................. 3-3
3.3 Economic and Energy Benefits ............................................................................ 3-4
4.0 Deployment of Research Funding ................................................................................ 4-1 4.1 Discussion Framework......................................................................................... 4-1 4.2 Visualizing Research Objectives ......................................................................... 4-2
4.3 Current Research Initiative Examples ................................................................. 4-2 4.3.1 WEF and WERF ........................................................................................ 4-2 4.3.2 Department of Energy ............................................................................... 4-2
4.3.3 National Science Foundation ..................................................................... 4-3 4.3.4 U.S. Environment Protection Agency ....................................................... 4-3 4.3.5 International Example ............................................................................... 4-4
4.3.6 Wastewater Utilities .................................................................................. 4-4 4.4 Ideas to Maximize Effectiveness of Research Funding Deployment .................. 4-4
4.4.1 Collaborations ........................................................................................... 4-4 4.4.2 Increasing Partnerships between Research Institutions and Utilities ........ 4-5 4.4.3 Stimulating Research Activity ................................................................... 4-5
4.4.4 Grant Size .................................................................................................. 4-5 4.4.5 Grant Types ............................................................................................... 4-5
4.4.6 Team Organization .................................................................................... 4-6 4.5 Sample Framework to Maximize the Impact of Increased Research .................. 4-6
4.5.1 WERF “Restocking” – $5 Million ............................................................ 4-6
4.5.2 Centers of Excellence – $24 Million ......................................................... 4-6
4.5.3 Seed and Subsequent – $21 Million .......................................................... 4-6
References ................................................................................................................................... R-1
Assessment of Technology Advancements for Future Energy Reduction xi
ES-1 Approximate Technology Readiness Levels ................................................................ ES-2
ES-2 Approximate Level of Economic Benefit ..................................................................... ES-5
ES-3 Key Innovation Approaches in Existing Technology or Scientific Areas .................... ES-6
2-1 Technology Readiness Levels .......................................................................................... 2-2
2-2 Mainstream Shortcut Nitrogen Removal ......................................................................... 2-4
2-3 Anaerobic Communities .................................................................................................. 2-7
2-4 Improved Biogas Conditioning Approaches .................................................................... 2-9
2-5 Anaerobic Digestion Pretreatment ................................................................................. 2-11
2-6 Aerobic Granular Sludge ............................................................................................... 2-13
2-7 CANDO ......................................................................................................................... 2-16
2-8 Higher Hydrocarbon Production from Biosolids ........................................................... 2-18
2-9 Higher Hydrocarbon Production from Biogas or Bioliquids ......................................... 2-21
2-10 Enhanced Methane Production from Anaerobic Digestion ........................................... 2-24
2-11 Food Waste Co-Digestion .............................................................................................. 2-26
2-12 Hydrogen Production from Wastewater ........................................................................ 2-29
2-13 Gasification and Pyrolysis ............................................................................................. 2-31
2-14 Anaerobic Mainstream Treatment ................................................................................. 2-35
2-15 Microbial Fuel Cells ...................................................................................................... 2-38
2-16 Microbial Electrolysis Cells ........................................................................................... 2-41
2-17 Supercritical/Subcritical Water Oxidation for Sludge Treatment .................................. 2-43
2-18 Integration of Algal Treatment and Harvesting ............................................................. 2-45
2-19 Thermally Regenerative Ammonia-Based Batteries (TRAB) ....................................... 2-48
3-1 Approximate Technology Readiness Levels ................................................................... 3-1
3-2 Approximate Level of Economic Benefit ........................................................................ 3-4
3-3 Approximate Level of Energy Benefit ............................................................................. 3-5
LIST OF TABLES
xii
ES-1 Technology Prioritization Based on TRL and Deployment Timeline .......................... ES-3
ES-2 Approximate Sector Energy “Impact” vs. Technology Readiness Level ..................... ES-4
1-1 Technology Prioritization ................................................................................................ 1-2
1-2 Equipment Prioritization .................................................................................................. 1-2
1-3 Management Prioritization............................................................................................... 1-3
3-1 Technology Prioritization Based on TRL and Deployment Timeline ............................. 3-2
3-2 Technology Prioritization Based on Technology Readiness Level vs.
Approximate Sector Energy “Impact” ............................................................................. 3-3
LIST OF FIGURES
Assessment of Technology Advancements for Future Energy Reduction xiii
A Amps
AFMBR Anaerobic fluidized bed membrane bioreactor
AMBR Anaerobic membrane blanket reactor
AnMBR Anaerobic membrane bioreactor
AOB Ammonia-oxidizing bacteria
ARPA-E Advanced Research Projects Agency-Energy
ASP Activated sludge process
BES Bioelectrochemical system
BETO Bioenergy Technologies Office
BNR Biological nutrient removal
BOD Biochemical oxygen demand
°C Degree(s) Celsius
C Carbon
CAPEX Capital expenditures
CH4 Methane
CHP Combined heat and power
CO Carbon monoxide
CO2 Carbon dioxide
COD Chemical oxygen demand
DAF Dissolved air flotation
DAMO Denitrifying anaerobic methane oxidation
DNA Deoxyribonucleic acid
DO Dissolved oxygen
DOE U.S. Department of Energy
DWU Dallas Water Utilities
EBPR Enhanced biological phosphorus removal
EERE Office of Energy Efficiency and Renewable Energy
EPRI Electrical Power Research Institute
EPWRR Energy-Positive Water Resource Recovery
ERC Engineering Research Center
FOG Fats, oils, and grease
LIST OF ACRONYMS AND ABBREVIATIONS
xiv
GHG Greenhouse gas
gpd Gallon(s) per day
gpm Gallon(s) per minute
H2 Hydrogen gas
H2S Hydrogen sulfide
HRT Hydraulic retention time
HTL Hydrothermal liquefaction
INFEWS Innovations at the Nexus of Food, Energy, and Water Systems
kg Kilogram(s)
kW Kilowatt(s)
kWh Kilowatt-hour(s)
L Liter(s)
LA Los Angeles
LED Light-emitting diode
LIFT Leaders Innovation Forum for Technology
m2 Square meter(s)
m3 Cubic meter(s)
MBfR Membrane biofilm reactor
MEC Microbial electrolysis cell
MFC Microbial fuel cell
mg Milligram(s)
MG Million gallons
mgd Million gallons per day
MPa Megapascal
MxC Microbial fuel cell-based technology
N Nitrogen
N2O Nitrous oxide
NOB Nitrite-oxidizing bacteria
NPDES National Pollutant Discharge Elimination System
NSF National Science Foundation
NYC DEP New York City Department of Environmental Protection
NYSERDA New York State Energy Research and Development Authority
Assessment of Technology Advancements for Future Energy Reduction xv
OCSD Orange County Sanitation District
OFMSW Organic fraction of municipal solid waste
OPEX Operating expenditures
P Phosphorus
PAH Polycyclic aromatic hydrocarbon
PG&E Pacific Gas and Electric Company
PHA Polyhydroxyalkanoate
RAS Return activated sludge
R&D Research and development
RD&D Research, development, and demonstration
RDD&D Research, development, demonstration, and deployment
RNA Ribonucleic acid
SBR Sequencing batch reactor
SBIR Small Business Innovation Research
SRT Solids retention time
TAG Technology Approval Group
TPAD Temperature-phased anaerobic digestion
TRAB Thermally regenerated ammonia battery
TRL Technology Readiness Level
TSS Total suspended solids
TWAS Thickened waste activated sludge
UASB Upflow anaerobic sludge blanket reactor
UC University of California
U.S. EPA U.S. Environmental Protection Agency
VFA Volatile fatty acid
VS Volatile solids
WAS Waste activated sludge
WASAC Waste activated sludge anaerobic contact
WEF Water Environment Federation
WERF Water Environment Research Foundation
WPCP Water pollution control plant
WRRF Water resource recovery facility
xvi
Assessment of Technology Advancements for Future Energy Reduction ES-1
EXECUTIVE SUMMARY
ES.1 Purpose
The wastewater industry is continuously seeking new technologies that will reduce the
need for purchased energy and improve its ability to beneficially recover resources. In addition,
within energy-positive technologies such as co-digestion that have begun to see wide levels of
deployment, there are continuing efforts to improve performance. This research reviews several
specific technology areas in an effort to assess their current level of maturity and potential
opportunities for adoption. The review also considers which wastewater treatment, solids
stabilization, and energy generation technologies are of greater interest relative to established
technologies, considering factors such as:
Magnitude of incremental energy efficiency improvement over existing technologies.
Reduced life-cycle cost.
Manageable safety and operational risks.
Environmental co-benefits such as improvements in effluent quality, or reduced greenhouse
gas (GHG) emissions, conventional air emissions, or chemical use.
ES.2 Methods
Eighteen technology areas were selected for the technology maturity assessment.
Researchers representing academic institutions, wastewater utilities, government agencies, and
wastewater industry organizations provided their views of these technologies based on their
knowledge of the status of current research and development (R&D) efforts. Input was gathered
via survey and workshop participation.
Because accelerated advancement in these technologies is contingent upon increasing
ongoing research progress, the workshop participants also discussed approaches to improving the
effective deployment of research grants. In the context of potential increased future funding,
participants weighed in on optimizing factors such as grant size, type, number, targeted team
organization, and selection/award criteria.
ES.3 Findings: Technology Maturity
The estimated Technology Readiness Level (TRL) statuses of the reviewed technology
areas are summarized in Table ES-1. Low TRL levels correspond to early phases of research. As
noted at the bottom of Table ES-1, some technology areas covered by this research were new
approaches to established technologies or scientific areas, so these technology areas were not
assessed for TRL.
ES-2
Table ES-1. Approximate Technology Readiness Levels.
Technology Readiness
Level TRL
Description Technology Areas
1-3
Basic or applied research
Critical function
Thermally regenerated ammonia batteries (TRABs).
Membrane production of hydrogen from wastewater
Microbial fuel cells (MFCs).
4-6 Lab testing
Prototype
Microbial electrolysis cells (MECs).
Higher hydrocarbon production: biosolids.
Higher hydrocarbon production: biogas/bioliquids.
Mainstream shortcut nitrogen (N).
Nitrous oxide (N2O) production to supercharge engines.
Mainstream anaerobic treatment.
Pyrolysis and gasification.
7-9 Pilot system
Commercial design
Deployment
Supercritical water oxidation for sludge treatment.
Aerobic granular sludge systems.
Existing
technologies
or scientific
areas: new
approaches
Modifications to deployed
technologies
Fundamental understanding of anaerobic communities
Biogas cleanup.
Pretreatment processes for anaerobic digestion.
Enhanced methane (CH4) from anaerobic digestion (other than co-digestion
and pretreatment).
Food waste co-digestion.
Assessment of Technology Advancements for Future Energy Reduction ES-3
Figure ES-1 compares the research needs for new technologies (based on TRL) to the
deployment timelines projected by the survey respondents. The estimated deployment timelines
ranged from approximately five years to 20 years. Technologies in the blue lower left quadrant
(mainstream shortcut nitrogen [N] and pyrolysis/gasification) appear most likely to be adopted in
the near term because these technologies are the most mature and the deployment timeline is
estimated to be relatively short.
Figure ES-1. Technology Prioritization Based on TRL and Deployment Timeline.
ES-4
The TRL was also compared to a composite gauge of impact on wastewater industry
energy use based on estimated levels of energy savings, applicability, and size niche
considerations. Figure ES-2 depicts the relative positions of the technologies based on these
criteria. This analysis implies that the two technologies in the upper right corner (mainstream
shortcut N removal and mainstream anaerobic treatment) will have the greatest impact on energy
use in the wastewater sector in the near term.
Figure ES-2. Approximate Sector Energy “Impact” vs. Technology Readiness Level.
Assessment of Technology Advancements for Future Energy Reduction ES-5
Survey respondents were also asked to gauge the economic viability of the technologies
based on energy savings relative to the cost of retrofits. Table ES-2 summarizes these results.
Most technologies were expected to be used in new projects or “end of useful life” retrofits. This
economic benefit level implies a longer deployment timeline because wastewater assets are fairly
long-lived and new projects are infrequently initiated.
Table ES-2. Approximate Level of Economic Benefit.
Economic Benefit Level Technology Area
Retrofits of existing equipment are likely to be cost-effective. Mainstream shortcut nitrogen.
Most likely to be used in new projects and retrofits triggered by
“end of useful life.”
Mainstream anaerobic treatment.
Aerobic granular sludge systems.
Pyrolysis and gasification.
Membrane production of hydrogen from wastewater.
Microbial electrolysis cells.
Supercritical water oxidation for sludge treatment.
Microbial fuel cells.
N2O production to supercharge engines.
Thermally regenerated ammonia batteries.
Somewhat challenging to make this technology economically
beneficial.
Higher hydrocarbon production: biosolids.
Higher hydrocarbon production: biogas/bioliquids.
ES-6
As noted previously, some of the technologies considered by this research are
enhancements or advancements in existing areas. Table ES-3 provides examples of the key
innovation approaches identified by participants for these technologies.
Table ES-3. Key Innovation Approaches in Existing Technology or Scientific Areas.
Technology or Scientific Area Key Areas Example Approaches
Fundamental understanding
of anaerobic communities
• Molecular measurements to better
understand system functions.
• RNA, not just DNA.
• Other real-time assessments, viable in a
plant operations setting.
• Protein analysis.
• Process stability indexing and the tools
to monitor it.
• Process performance under very cold
temperatures (e.g., below 12C).
• Online volatile acid monitoring,
Vmax, or biomarkers.
• To be developed.
Biogas cleanup
• Methods to detect low levels of biogas
constituents such as siloxanes.
• To be developed.
Pretreatment processes for
anaerobic digestion
• Identifying highest-value carbon (C)
product.
• Producing products other than
methane.
Enhanced/accelerated
methane production from
anaerobic digestion (other
than co-digestion and
pretreatment)
• Defining systems and operations
practices that maximize the benefits of
biogas generation.
• Determining optimal feeding
strategies.
• Definition of the microbial
communities involved in digestion.
• Direct interspecies electron transfer
(DIET) to accelerate and stabilize
anaerobic digestion.
• Maximizing C feed to digestion.
• Streamline and strengthen
electron exchange between
syntrophs and methanogens.
• Waste activated sludge (WAS)
anaerobic contact.
Food waste co-digestion • Rapid waste characterization and
process model input.
• Improved materials
characterization techniques.
• Better define the synergistic effects of
food waste co-digestion.
• Improved C fractionation.
Assessment of Technology Advancements for Future Energy Reduction ES-7
ES.4 Findings: Enhanced Deployment of Research Funding
Workshop participants discussed several ideas to maximize the effectiveness of a
hypothetical infusion of $50 million per year of additional future research funding, including:
Collaborations. Proposed collaborative approaches included test bed facilities, research
centers to tackle individual multi-year projects, and third-party validation services.
Wastewater utility partnerships. Programs that connect new technology collaborations
with wastewater utilities were noted to be most effective if they can be timed to address a
specific utility need. In other words, utilities will be most interested in demonstrating or
piloting new technologies when they are evaluating alternatives to meet a pending process
objective such as replacing aging equipment, increasing nutrient removal, or expanding plant
capacity. Collaborations with utilities were also seen as most effective when they were long-
term, almost permanent.
Approaches to stimulate new research activity. Participants proposed creating challenge
prizes or grants to stimulate grassroots ideas and enthusiasm. Another suggestion proposed
deploying an annual group of postdoctoral researchers who would be trained as a cohort,
networked to share ideas, and then deployed to various utilities to work on site-specific
research projects as a means to keep good researchers active in the industry.
Grant types. Some participants proposed devoting half of the hypothetical $50 million to
two centers organized geographically around certain needs, with a five-year funding period.
Beyond five years, the centers would be funded through subscription payments from private
entities. Others proposed add-on grants to provide a pool of money for third-party oversight
of demonstration projects. Proponents felt that this auxiliary funding would make research
results more powerful.
ES-8
Assessment of Technology Advancements for Future Energy Reduction 1-1
CHAPTER 1.0
INTRODUCTION
The wastewater industry is continuously seeking new technologies that will reduce the
need for purchased energy and improve its ability to beneficially recover resources. In addition,
within technologies that have begun to see wide levels of deployment, such as co-digestion,
efforts to improve performance continue. This research reviews several specific technology areas
in an effort to assess their current level of maturity and potential opportunities for adoption.
1.1 Research Context
Several previous studies have documented new and emerging technologies, often with an
eye toward methods that significantly reduce energy use. These studies provide useful technical
background and previous assessments of the technologies reviewed in this publication.
1.1.1 EPA Manual of Emerging Technologies for Wastewater Treatment and
In-Plant Wet Weather Flow
Chapter 3 of the U.S. Environmental Protection Agency (U.S. EPA) Manual of Emerging
Technologies for Wastewater Treatment and In-Plant Wet Weather Flow (U.S. EPA, 2013)
discusses several of the technologies addressed in this report, including deammonification,
aerobic granular sludge, anaerobic mainstream systems such as anaerobic membrane blanket
reactors (AMBR) or anaerobic membrane bioreactors (AnMBR), and microbial fuel cells
(MFCs). Chapter 6 provides assessments of energy conservation measures. Most of the methods
featured in this manual are focused on optimizing aeration energy via methods such as enhanced
controls or improved diffuser efficiency.
1.1.2 WERF Technology Roadmap for Sustainable Wastewater Treatment Plants
in a Carbon-Constrained World
The 2010 Water Environment Research Foundation (WERF) report, Technology
Roadmap for Sustainable Wastewater Treatment Plants in a Carbon-Constrained World
(Technology Roadmap, Project No. OWSO4R07d), presented a roadmap for the next generation
of wastewater treatment processes, with a focus on resource recovery, including energy/carbon
(C) recovery.
The Technology Roadmap visualized the research status and projected timeline
for several approaches, grouped under 1) technologies, 2) equipment innovations, and
3) management strategies. A quadrant framework was used to prioritize future approaches
proposed by work group participants, with the most developed, shortest timeline in the lower left
corner. Technologies are depicted in this manner in Figure 1-1, equipment in Figure 1-2, and
management strategies in Figure 1-3.
It is interesting to note that in the five years since the Technology Roadmap report was
published, several of the listed technologies have progressed and in some cases become
established, while others are still emerging. The technologies that have gained traction in the
wastewater industry are highlighted in Figures 1-1 through 1-3.
1-2
Figure 1-1. Technology Prioritization*.
Figure 1-2. Equipment Prioritization. *Source: Technology Roadmap for a Sustainable Wastewater Treatment Plants in a Carbon-Constrained World
(WERF, 2010), with modifications.
Technologies that have gained
traction since 2010
Technologies that have gained
traction since 2010
Assessment of Technology Advancements for Future Energy Reduction 1-3
Figure 1-3. Management Prioritization. Source: Technology Roadmap for a Sustainable Wastewater Treatment Plants in a Carbon-Constrained World
(WERF, 2010), with modifications.
1.1.3 Parallel DOE Initiative
This research included collaboration with a federal effort to gain insights and identify
specific technical and non-technical barriers that are hindering development and deployment of
the water resource recovery facilities of the future. This initiative was organized around three
workshops:
Bioenergy Technologies Office (BETO) in the U.S. Department of Energy’s (DOE)
Office of Energy Efficiency and Renewable Energy (EERE) Workshop focused on
commercial production of drop-in hydrocarbon fuels from wet waste biomass. The
participants identified 17 advancement activities as high in priority in the areas of pre-
processing, process research, process engineering, and analysis. Some of these activities
apply broadly to wet waste conversion (including wastewater sludge), while others apply to
specific technologies.
BETO-Sponsored Workshop on Hydrogen, Hydrocarbons, and Bioproduct Precursors
from Wastewaters. It gathered experts to share information and identify the current status
and research, development, and demonstration (RD&D) possibilities for production of
hydrogen and higher hydrocarbons (containing four or more C atoms) from wastewaters
using biological, biochemical, and other techniques. In particular, the workshop focused on
microbial fuel cell-based technologies (MxCs) and AnMBRs.
Technologies that have gained
traction since 2010
1-4
The National Science Foundation (NSF), EPA, and DOE Jointly Hosted Workshop on
Energy-Positive Water Resource Recovery (EPWRR) to envision what a state-of-the art
facility would look like in 20 or more years, assessing gaps and hurdles, and considering
where additional research, development, demonstration, and deployment (RDD&D) could
have the greatest impact.
1.2 Project Overview
This section presents the research objectives, scope, and approach of this project.
1.2.1 Research Objective
The intent of this research was to consider which wastewater treatment, solids
stabilization, and energy generation technologies are of greater interest relative to established
technologies, considering factors such as:
Magnitude of incremental energy efficiency improvement over existing technologies.
Reduced life-cycle cost.
Manageable safety and operational risks.
Environmental co-benefits such as improvements in effluent quality, or reduced GHG
emissions, conventional air emissions, or chemical use.
1.2.2 Research Scope and Approach
Eighteen technologies were selected for the technology maturity assessment. The
following criteria were used to narrow the list of technologies:
Degree of energy benefit.
Degree of maturity or experience in North America.
Research and development (R&D) status ranging from theory to pilot scale.
Potential for scalability to have significant impact at facilities of various sizes.
Widespread applicability to existing water resource recovery facilities (WRRFs).
Participants were asked to complete a survey to gather information regarding research
needs, expected maturity timeline, and expected magnitude of the energy benefit (survey
questions included in Appendix A). Survey findings were reviewed and refined in a workshop
setting on June 11, 2015.
Because progress with these technologies is contingent upon ongoing research progress,
the workshop participants also discussed factors affecting deployment of research grants,
including grant size, type, number, targeted team organization, and selection/award criteria.
1.3 Report Organization
This report is divided into the following chapters that document the methodology used to
collect data and the findings in various focus areas:
Chapter 1.0: Introduction
Chapter 2.0: Technology Summaries
Chapter 3.0: Technology Comparisons and Prioritization
Chapter 4.0: Deployment of Research Funding
Assessment of Technology Advancements for Future Energy Reduction 2-1
CHAPTER 2.0
TECHNOLOGY SUMMARIES
Technologies considered in this assessment were grouped into the following major categories:
Improving energy efficiency in existing treatment facilities/processes: Energy-saving
alternatives to conventional biological nutrient removal (BNR), improvements to biogas
scrubbing, and digestion pretreatment.
Enhancing chemical energy recovery: Digestion and co-digestion technology
enhancements and other fuel production approaches, pyrolysis, and gasification.
Combining efficient treatment with energy recovery: Transformative technologies that
replace conventional aerobic treatment systems and/or provide new methods of recovering
energy from wastewater.
This chapter summarizes the technology maturity survey and workshop findings related
to each of the eighteen technologies within these groups. Survey respondents answered questions
for which they indicated either 1) very high level of expertise, 2) high level of expertise, or
3) very high level of interest. The summaries found in this chapter sometimes draw a distinction
between the answers given by respondents with high expertise (often from academic settings)
and those with high interest (often from wastewater utility settings). In some cases, the number
of respondents with high expertise or interest was relatively few, so the number of respondents is
shown for each technology as a gauge for sample size.
It should be noted that this report is focused on technology maturity status and hurdles.
Refer to the References section for related publications that include more detailed technology
descriptions and background.
2-2
2.1 Characterizing Technology Maturity Levels
Panel members assessed maturity levels using the DOE “Technology Readiness Level”
(TRL) scale (DOE, 2011). This is a fairly granular scale, using nine levels to describe the
progression from basic research to commercial deployment, as summarized in Table 2-1.
Table 2-1. Technology Readiness Levels.
Technology Readiness Level Description
1
Basic research: basic principles observed.
2 Applied research: initial practical applications identified.
3
Critical function: studies and initial laboratory measurements to validate analytical
predictions of separate elements of the technology.
4
Laboratory testing/validation of alpha prototype component/process: design,
development, and lab testing of technological components.
5
Laboratory testing of integrated/semi-integrated system: component and/or process
validation in relevant environment.
6
Prototype system verified: system/process prototype demonstration in an
operational environment.
7
Integrated pilot system demonstrated: demonstration of an actual system prototype
in a relevant environment.
8 System incorporated in commercial design: pre-commercial demonstration.
9 System proven and ready for full commercial deployment: actual system proven.
Assessment of Technology Advancements for Future Energy Reduction 2-3
2.2 Improving Energy Efficiency in Existing Treatment Facilities/Processes
The following technologies include incremental changes to existing processes, including
energy-saving alternatives to conventional BNR, improvements to biogas scrubbing, and
digestion pretreatment.
2.2.1 Deammonification (Mainstream Shortcut Nitrogen Removal)
Low-energy (shortcut) deammonification systems using anammox bacteria in lieu of
conventional nitrifying bacteria have been implemented at full-scale for treating warm, high-
strength sidestreams from dewatering digested solids. This short-cut nitrogen removal
technology is currently being researched and adapted for use in mainstream treatment.
Deammonification involves anammox bacteria working synergistically with ammonia-oxidizing
bacteria (AOB) to oxidize ammonium without organic C to produce nitrogen (N) gas. The
overall deammonification process requires less oxygen to remove nitrogen, thereby reducing the
energy demand on the aeration process. In addition, the solids retention time (SRT) pressure used
to suppress nitrite-oxidizing bacteria (NOB) results in a capacity benefit.
This technology is the subject of significant research efforts and pilot testing, but
currently lacks any full-scale facilities in the U.S. and associated performance and stability data.
There is also a need for advanced control systems to continuously monitor in-process and
upstream variables that affect operational parameters and allow timely operational adjustments.
Some of the most significant hurdles to widespread implementation of this technology are
regulatory. For example, an effluent N concentration of 2-3 milligrams per liter (mg/L) is
required to maintain high growth rates in mainstream deammonification processes, but this
concentration is too high for plants that must meet very strict N effluent permit limits, in which
case a polishing step must be added. Daily and weekly permit limits are also problematic, with
longer averaging periods or 95th
percentile approaches significantly reducing permit risks.
Workshop participants discussed the prospective energy savings from mainstream
shortcut N removal. The primary energy benefit was tied to concurrent C diversion from
upstream processes. In other words, because the shortcut N removal process requires little or no
carbon, upstream processes can be optimized to maximize C feed to anaerobic digestion and
minimize secondary aeration. Upstream processes could include 1) mainstream anaerobic
treatment, 2) A-stage reactors, with or without chemical enhancement, and 3) enhanced primary
treatment. Each of these three scenarios would have varying impacts on energy savings because
of their relative impact on particulate, colloidal, and soluble C fractions.
A secondary energy benefit could be derived from lower dissolved oxygen (DO) set
points, because shortcut N removal processes can operate at lower DO concentrations than
conventional nitrification processes.
Table 2-2 summarizes survey and workshop discussion findings regarding mainstream
shortcut N removal.
2-4
Table 2-2. Mainstream Shortcut Nitrogen Removal.
Respondents: 19
• Very high level of expertise: 5
• High level of expertise: 5
• High level of interest: 9 Majority Consensus Response Contrary Response(s)
How would you characterize the current technology status?
High level of
expertise
Two thirds of respondents classified the technology as prototype
or pilot scale.
One third of respondents classified
the technology as applied research
with an identified application.
High level of
interest
Prototype or pilot scale.
Applied research with an identified application
(40% each).
One respondent classified the
technology as ready for full-scale
implementation.
What are the most pressing research needs for advancing this technology?
High level of
expertise • Gaining better control of the system and population
selection.
• Understanding overall system operation variability from
location to location.
• Improve prediction and control of long-term energy costs
and operating costs.
• Techniques such as fixed-film anammox for residual
polishing to meet low N concentration permit
requirements.
• Development of sensor-mediated control strategies that
enhance efficiency and stability.
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of
expertise
Lack of information, risk aversion, and experience with real-
time control.
High level of
interest
Perceived process risk (long recovery times), lack of design
standards, and perception of complexity verses benefits.
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of
expertise
Most likely to be used in new projects and retrofits triggered by
"end of useful life" situations (making adoption slower)” (55%).
Retrofits of existing "adequate"
equipment could be cost-effective
(45%).
High level of
interest
Retrofits of existing “adequate” equipment could be cost-
effective (60%).
Comments:
• The nitrite shunt mode should be economically beneficially
if modifications are related only to process control. The
nitritation + anammox is a challenge at mainstream
concentrations.
• They could be cost-effective if use of existing tankage is
sufficient from a size/SRT perspective.
Most likely to be used in new
projects and retrofits triggered by
"end of useful life" situations
(making adoption slower)(40%).
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of
expertise
Industry best practice (66%).
Potential for universal application
(11%).
A niche application (22%).
High level of
interest
Industry best practice (57%). Only 14% responded that it has the
potential for universal application
while 28% responded that it is a
niche application.
Assessment of Technology Advancements for Future Energy Reduction 2-5
Respondents: 19
• Very high level of expertise: 5
• High level of expertise: 5
• High level of interest: 9 Majority Consensus Response Contrary Response(s)
Does this technology have scale considerations or niches?
High level of
expertise
No scale or niche limitation (66%).
10 mgd minimum size (33%).
High level of
interest
4 of 5 respondents indicated that there are no scale or niche
limitations, while one believed there to be a 100 mgd limit.
The scale is one part with larger
plants being more likely to adopt.
Also, more likely in an existing facility
that is set up for BNR with the ability
to have multiple zones of varying DO.
If you had to guess, how many years will it take to overcome technical challenges? Comments
High level of
expertise
1-3 years and 3-5 years (33% each).
5-10 years (22%).
Greater than 10 years (12%).
High level of
interest
1-3 years and 3-5 years (40% each). 5-10 years (20%).
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North
American installations)?
High level of
expertise
3-5 years (66%).
1-3 years (33%).
High level of
interest
1-3 years (60%). 3-5 years (40%).
What performance metrics are required to make this technology economically viable?
High level of
expertise • Cost, energy, and C emissions reductions based on real-
world data with demonstration of effective N removal.
• Achieving sufficient retention time for biomass.
• Hitting discharge limits for N without a polishing step.
High level of
interest • A process that demonstrates ammonia removal with
defined chemical, energy, oxygen, and reasonable process
metrics (retention time).
• Strong financial benefit to the implementing utility.
What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of
expertise
Greater than 50% (40%) and 10-25% savings (37% each).
Greater than 50% savings contingent on upstream C removal
as noted above.
25-50% savings, <10% savings
(12.5% each).
High level of
interest
10-25% savings (75%). 25-50% savings (25%).
2-6
2.2.2 Fundamental Understanding of Anaerobic Communities
Future strategies for energy-efficient or energy-positive wastewater treatment will rely
heavily on anaerobic systems. A fundamental understanding of heterotrophic anaerobic
communities' activities and interactions is necessary to advance anaerobic approaches to
secondary/mainstream treatment, and digestion advancement. Examples of this type of research
include:
Microbial ecology studies, improving control and optimization of microbial communities.
Investigating biological intermediates.
Understanding interspecies electron transfer, biofilms, and granules.
Fundamentally understanding changes in community structure with change loadings and
materials composition.
Identifying metabolic pathways to improve the cost benefit of digestion.
Investigating short-term anaerobic contact flocculation mechanisms.
Recovering carbon in forms that can be used in N removal.
Making hydrogen in lieu of using methanogens to produce methane (CH4).
Discovering improved systems modeling for design development.
Studying yields and kinetics for phase-separated systems.
Improving monitoring and controls for systems managers.
Refining process performance under very cold temperatures (e.g., below 12C)
Workshop attendees discussed approaches to leverage anaerobic communities to improve
current utilities operations and to advance the state of the art. This research is needed to drive the
further development and refinement of mainstream anaerobic processes and further advance the
anaerobic digestion process. Molecular tools present a promising avenue to enhance our
understanding of anaerobic communities. The application of reverse transcript ribonucleic acid
(RNA) techniques can provide a better understanding of system function, beyond the
presence/absence type of information that current deoxyribonucleic acid (DNA)-based analysis
provides. Additional research into protein activity in anaerobic systems would also further the
industry’s understanding of system function. However, to be effective, these tools need to be
integrated to provide near real-time assessments and demonstrated to be viable in a plant
operations setting.
Along with molecular techniques to monitor and define community form and function,
additional process metrics and monitoring techniques for daily operations are needed. An area of
need identified by the group is process stability indexing and the tools to monitor it, such as
online volatile acid monitoring, Vmax, or biomarkers for varying substrates of interest.
Through a better understanding of the function of anaerobic communities, the
fundamental question of do we engineer the community or process? may be better answered by
examining what better anaerobic digester process control and design models could be developed.
Assessment of Technology Advancements for Future Energy Reduction 2-7
Table 2-3 summarizes survey and workshop findings regarding energy-related
applications of research into the function of anaerobic communities.
Table 2-3. Anaerobic Communities.
Respondents: 17
• Very high level of expertise: 7
• High level of expertise: 8
• High level of interest: 2 Response
What future applications do you foresee resulting from research related to fundamental understanding of heterotrophic
anaerobic communities?
High level of expertise Mainstream anaerobic treatment to increase biogas production was the most
prevalent area of potential growth.
Other areas identified include:
• Enhanced digestion (high temp., high ammonia).
• Improved fermentation.
• Anaerobic membrane reactors.
• Denitrifying anaerobic methane oxidation (DAMO).
• Sulfide oxidation.
• Biological hydrogen, electricity, and biofuel production; conversion of influent
organic carbon to products of commercial value (to chemical industry, textile
manufacturing, etc.).
• Impact of process parameters such as organic loading and cell density on
conversion.
• Hybrid anaerobic/aerobic mainstream treatment.
• Anaerobic contact reactors to sorb colloidal material and particulate carbon,
enhancing digestion.
High level of interest • Mainstream anaerobic treatment.
• Approaches to intensify the anaerobic digestion process (reduced SRT,
increased organic loading and digester sizing).
How will these applications impact WRRF energy use?
High level of expertise All respondents indicated that processes/approaches centered around anaerobic
conversion of carbon, in place of traditional aeration, have the potential to reduce
the energy requirements of municipal WRRFs, although there was a range of
expectations regarding the extent of the benefit achieved. It was further noted that
these technologies need to be coordinated with end uses to maximize benefits (e.g.,
VFA generation for conversion to biodiesel).
High level of interest Those with a high level of interest in this particular topic indicated that savings
through mainstream anaerobic treatment would save on energy costs but also noted
that enhancement/intensification of anaerobic digestion can save energy. These
individuals further noted that these efforts must be coordinated with other resource
recovery efforts to maximize the benefit.
2-8
2.2.3 Improved Biogas Conditioning
Biogas conditioning systems have become industry standard for use in removing
contaminants that increase engine maintenance, including moisture, hydrogen sulfide (H2S), and
siloxane compounds. Biogas conditioning systems used for vehicle fuel (BioCNG) or natural gas
pipeline injection (biomethane) also separate the carbon dioxide (CO2) gas fraction.
These systems impact plant energy consumption, because of both their impact as parasitic
electrical loads and their expense in enabling reliable power generation. Improvements in these
systems enhance biogas utilization by reducing life-cycle costs. Examples of these considerations
include:
Loss of biogas in purge streams for some regenerative and CO2 separation systems.
Frequent and labor-intensive media replacement for H2S removal systems.
Reduced engine maintenance intervals.
The expert reviewers indicated that these technologies are mature and their further
development was going to be heavily driven by market conditions. However, it was noted that
some fundamental research into low detection levels for biogas constituents such as siloxanes
would be beneficial as gas quality standards have been tightened in some areas to close to the
limits of detection of current methods. Another area where research may benefit the industry is in
smaller-scale systems that are economical.
Table 2-4 highlights the improved biogas conditioning approaches being tracked by
survey respondents.
Assessment of Technology Advancements for Future Energy Reduction 2-9
Table 2-4. Improved Biogas Conditioning Approaches.
Respondents: 16
• Very high level of expertise: 6
• High level of expertise: 8
• High level of interest: 2
Technology Contaminant (s) How is Technology Superior
to Existing Systems Current Challenges Pilot or New Installations
Membranes Siloxanes, CO2 The cost and energy usage of
these systems has come down
in the past 5 years. BioCNG is
valuable as a vehicle fuel, but
CO2 typically needs to be
removed. Membranes are now
less expensive.
Still need to
reduce energy of
CO2 removal and
BioCNG
compression.
Janesville, WI
Regenerable
adsorption
(pressure or
temperature
swing,
molecular gate)
Siloxanes Some enable higher-efficiency
energy generation.
Application and
translation from
existing
technologies in
some cases and
demonstration in
other cases.
Methane loss
during
regeneration.
Biological
treatment
example
technology:
BioGasclean
H2S More sustainable, less
chemical-intensive.
Stability, costs,
upsets,
size/space
requirements.
LA County is testing a
slightly aerated
biotrickling filter.
Solvent
separation
CO2 Better constituent removal
performance with new gas
quality requirements being
instituted.
Process
complexity and
limited
performance
data on systems
operated with
WRRF biogas.
Only aware of recent
installations on landfill
gas.
InnoSepra
CO2 A flue gas CO2 adsorbent,
which potentially requires
lower heat of absorption than
competing processes.
Bench-scale tests,
seeking funding for
pilots.
http://www.netl.doe.go
v/research/coal/carbo
n-capture/post-
combustion/sorbent-
innosepra
Water scrubbing H2S, CO2 No chemicals are needed; can
be used on low pressure gas;
only consumable is plant
water.
Size/space
requirements.
Demonstrated
only at small
scale.
OCSD is evaluating water
scrubbing after conducting
some very small-scale testing,
it may expand into a larger
demonstration project.
2-10
2.2.4 Pretreatment Processes for Anaerobic Digestion
In recent years, various processes have been developed to pretreat solids prior to
digestion, especially to break down refractory cell structures and particulate matter. The
objective of these pretreatment systems is primarily to increase 1) the rate of digestion,
2) volatile solids destruction, and 3) digester gas production. Some systems also improve
pathogen destruction and dewaterability and reduce digester reactor size requirements. Various
approaches have been developed. The thermal hydrolysis approach has attained commercial
viability and widespread interest, and was mentioned by almost all survey respondents. Other
systems are still in development.
Table 2-5 summarizes the various technologies being tracked by respondents. A few
other technologies were mentioned but not described by respondents (biological pretreatment,
ozonation, electron beam technology). Some challenges apply to several technologies:
Ability to predict increased methane yield and solids reduction performance at specific
plants.
Obstacles related to retrofits of existing equipment, footprint requirements.
Reducing energy inputs and achieving life-cycle sustainability.
Regaining utility trust, especially after several early pretreatment approaches did not really
work.
Prediction of process impacts on return streams, sludge viscosity, and rheology.
Expansion of treatment beyond waste activated sludge (WAS).
Highest-value carbon management strategies (methane or other carbon forms).
Assessment of Technology Advancements for Future Energy Reduction 2-11
Table 2-5. Anaerobic Digestion Pretreatment.
Respondents: 16
• Very high level of expertise: 6
• High level of expertise: 7
• High level of interest: 3
Technology How is Technology Superior
to Existing Systems Current Challenges Pilot or New Installations Thermal
hydrolysis
Reducing viscosity to allow
significant increase in loading
rates, Class A product,
compatible with co-digestion,
improved dewaterability.
Education, broad
acceptance.
DC Water
operational, Trinity
River planned
installation.
Chemical
treatment
“Lodomat”
Pretreatment of WAS in mixing
tank at ambient temperature
and pressure. Low chemical
consumption (nitrite and acid).
Increased biogas production.
Modified version can achieve N
removal via the nitrite pathway:
RAS NOB are killed while AOB
remain viable.
Full-scale trials needed
to verify the results.
Being developed by
University of Queensland.
Being implemented in
Australia at 7.9 mgd plant.
Caustic and
medium
temperature
treatment
“Lystek”
Caustic and medium-
temperature treatment with
high shear mixing. Synergies
with BNR, volume reduction,
biogas increase, liquid Class A
product.
Unknown. Several full-scale
installations in
Canada.
Microwave Break down particulate matter Lack of fundamental
understanding of the
mechanism of energy
transfer to particulates
and specificity in
wastewater treatment.
Research stage (Oak
Ridge National Lab).
Cavitation Low energy input required Demonstration of
increased methane yield
and solids reduction for
mixed TWAS and primary
sludge.
WERF and TAG are
organizing a
collaborative,
Upcoming Arisdyne
tests at several
utilities, including
Columbus, GA.
Combined
anaerobic/aerobic
treatment
Better dewaterability, less odor Minimal. Spokane, WA.
Electric-energy
processing
Improve digestion of secondary
solids
Small-scale results have
not been replicated at
full-scale.
OpenCEL Racine, WI,
Test at OCSD
(recently canceled).
Ultrasound,
sonication
No specific advantages listed High energy input and
insignificant digestion
improvement.
Anergia has tested
ultrasonic
conditioning .
2-12
2.2.5 Aerobic Granular Sludge Systems
Aerobic granular sludge uses granules in place of light biological floc structures for
secondary treatment and BNR. The granular structure in this process is stratified so that both
aerobic and anaerobic/anoxic layers are present and the biological processes for N, phosphorus
(P), and C removal occur simultaneously. Granular sludge reactors can be operated at higher
biomass concentrations, allowing higher loading rates while maintaining the longer SRT
necessary for stable nitrification. Reactors are most often configured as sequencing batch
reactors (SBRs). Some granular activated sludge systems could be operated at a low DO set point
for energy efficiency, while achieving total N removal. Granular sludge systems are the subject
of current WERF research project U1R14, Balancing Flocs and Granules for Activated Sludge
Process Intensification in Plug Flow Configurations.
Table 2-6 summarizes the survey and workshop findings regarding aerobic granular
sludge systems.
Assessment of Technology Advancements for Future Energy Reduction 2-13
Table 2-6. Aerobic Granular Sludge Systems.
Respondents: 9
• Very high level of expertise: 1
• High level of expertise: 6
• High level of interest: 2 Response
How would you characterize the current technology status?
High level of expertise Half of the respondents indicated that the technology was proven and ready for full
commercial deployment. The other half of the respondents indicated that the technology is
not developed to the commercial level yet, with responses ranging from the technology is at
the pre-commercial demonstration stage (33%) to the demonstration of a prototype (17%)
level of development.
Comments:
Need to expand on existing system configuration being operated in Europe: demonstrate
ability to integrate into existing WRRF.
Examples:
• Existing plants in operation in Europe and South Africa, and ~40 plants in the pipeline to
be designed by DHV (a Netherlands company commercializing this process).
• Lab studies done by the universities in U.S. (e.g., Belinda Sturm at Kansas).
• University of Michigan lab-scale system to achieve N removal and dissolved methane
removal from mainstream AnMBR effluent.
High level of interest Aerobic granular sludge was viewed by highly interested parties as not nearly as developed
as the Expert survey respondents. The technology is viewed as being strong but at the
laboratory level of evaluation with validation in a relevant environment.
What are the most pressing research needs for advancing this technology?
High level of expertise • Greater understanding of the engineering of the granule architecture, process biology,
chemistry, and physics.
• Better understanding on integrating the process into existing facilities, including plug flow
tankage. Consideration of external selectors (e.g., cyclone, screen, or settling column) to
manage granular cell mass and impart selection pressure to favor granule formation.
• Development operating parameters to make operations reliable and robust.
• Controls for operation under variable loading conditions.
• Integration with modeling elements (e.g., BioP).
• Development of metrics without being linked to a specific patent (e.g., DHV).
• Pilot-scale demonstration.
High level of interest • Improved understanding of mass transfer within the system.
• Environmental conditions required to maintain the appropriate ratios of different bacterial
populations within the system.
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of expertise • Challenges in retrofitting the technology into existing systems and a one-size-fits-all
approach.
• Education about the process and the need for greater education of the industry because
of the relative newness of the technology to the U.S. market.
• Potential impact of patents was raised as a potential barrier as well.
High level of interest The perception within the U.S. wastewater industry that the activated sludge process (ASP) is
the only solution.
2-14
Respondents: 9
• Very high level of expertise: 1
• High level of expertise: 6
• High level of interest: 2 Response
How economically beneficial do you expect this technology to be?
High level of expertise Retrofits of existing “adequate” equipment could be cost-effective (60%).
Comments:
• Retrofitting existing systems: according to DHV, can be done, but it is not clear if it is
economical.
• More realistic as a downstream process for anaerobic mainstream treatment.
High level of interest Retrofits of existing “adequate” equipment could be cost-effective (50%).
Most likely to be used in new projects and retrofits triggered by “end of useful life” situations
(making adoption slower) (50%).
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of expertise or interest A majority of respondents indicated that this technology has a broad level of applicability to
the industry, with 33% indicating near universal acceptance or as a transition to best
practice by a majority of plants vs. 25% indicating it is a niche market.
Does this technology have scale considerations or niches?
High level of expertise None.
Comment: DHV is designing plants of pretty good size.
High level of interest None.
If you had to guess, how many years will it take to overcome technical challenges?
High level of expertise 3-5 years (80%).
5-10 years (20%).
High level of interest The responses were evenly split between the 3-5-year range and the 5-10-year range.
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North American
installations)?
High level of expertise and
interest
3-5 years (40%).
5-10 years (40%).
1-3 years (20%).
What performance metrics are required to make this technology economically viable?
High level of expertise and
interest • Proof of performance for the system.
• Similar or better performance to activated sludge or biofilm systems.
• Reduced energy costs.
• Comparable surface overflow rates for setting.
• Demonstrated ability to manage seasonal temperature changes and wet weather events.
What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of expertise and
interest
Wide range of opinions on potential energy savings:
Less than 10% (3 responses).
25-50% reduction (2 responses).
Greater than 50% (1 response).
Comment: According to studies from the Netherlands, energy savings will depend on the
effluent water quality standard. Savings higher if integrated with C, N, and P cycling.
Workshop discussion: Workshop participants attributed energy savings to lower DO set
points and reduced internal mixed liquor pumping. Based on these two factors, the
anticipated energy reduction was less than 10%.
Assessment of Technology Advancements for Future Energy Reduction 2-15
2.3 Enhanced Chemical Energy Recovery
The following technologies improve chemical energy recovery, either via new types of
energy streams (nitrous oxide [N2O], hydrogen, higher hydrocarbons, syngas, pyrolysis oil), or
enhancements to methane production from existing anaerobic digestion and food waste co-
digestion techniques.
2.3.1 N2O Production to Supercharge Biogas Engines (e.g., CANDO)
The CANDO process operates in conjunction with the SHARON shortcut N process to
improve energy production. The CANDO process captures the high energy value of the N2O off-
gas from the sidestream treatment process. The effect of the CANDO N2O combustion process is
similar to jet propulsion or nitrous injection in race cars. SHARON is a well-established
sidestream treatment process, reducing sidestream oxygen demands by up to 25%, whereas the
CANDO process is an emerging process, recently tested at the Delta Diablo Sanitation District.
Table 2-7 summarizes the survey findings regarding the CANDO process.
2-16
Table 2-7. CANDO Process.
Respondents: 4
• Very high level of expertise: 1
• High level of expertise: 3
• High level of interest: 0 Majority Consensus Response Contrary Response(s)
How would you characterize the current technology status?
High level of
expertise
Demonstrated at the laboratory scale (66%) or pilot scale (33%) in a relevant
environment.
Skepticism regarding
whether this technology will
be feasible or cost-
effective.
What are the most pressing research needs for advancing this technology?
High level of
expertise
The process requires a stronger business case to make it successful including:
• Improved N2O utilization.
• Reduction in system complexity.
• Improved N2O recovery.
• Implementation beyond the sidestream to mainstream.
Comment: Sidestream treatment barrier may be reduced if co-digestion requires
strategies to manage increased N load.
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of
expertise • Process risk.
• Long-term reliability.
• Cost-effectiveness.
• Lack of regulatory and renewable energy drivers to adopt new technologies.
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of
expertise
There was a unanimous consensus that this technology is a niche technology.
Does this technology have scale considerations or niches?
High level of
expertise
10 mgd (1 response).
100 mgd (1 response).
Does this technology have scale considerations or niches?
High level of
expertise
The responses were divergent on the scale of facility this technology is suitable
for, with a low of 10 mgd to a high of 100 mgd. It was noted that in larger plants
with high N loads in sidestreams, there is a clearer energy benefit.
If you had to guess, how many years will it take to overcome technical challenges?
High level of
expertise
A majority of responses indicated that the CANDO process will take more than
10 years of additional development to overcome its technical challenges.
1-3 years (1 response).
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North American
installations)?
High level of
expertise
Greater than 10 years (2 responses). 3-5 years (1 response).
What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of
expertise
10% reduction or less (1 response).
10-25% reduction (2 responses).
What performance metrics are required to make this technology economically viable?
High level of
expertise
• >80% N conversion to N2O.
• >80% N removal.
• >1 kg-N/m3/d loading.
Assessment of Technology Advancements for Future Energy Reduction 2-17
2.3.2 Higher Hydrocarbons from Biosolids, Including HTL Methods
The focus of this research area is on developing higher-value fuel products from biosolids
feedstocks, including drop-in fuels to be compatible with existing transportation infrastructure
(e.g., petroleum-derived gasoline and diesel fuel). In this context, DOE has defined higher
hydrocarbons as molecules with four or more C atoms, produced from biosolids and other wet
organic wastes. This approach can be advantageous relative to digestion and biogas combined
heat and power (CHP) in cases where air permits are especially restrictive or electrical rates are
low.
This topic area encompasses many process approaches in various phases of development,
including hydrothermal liquefaction (HTL) and other techniques. As one survey respondent
noted, this topic requires a shift in thinking toward chemical synthesis because we have hardly
scratched the surface in terms of products, platforms, and pathways.
Workshop participants listed the following broad range of potential solids, liquids, and
gas hydrocarbon products that could be produced by various processes:
Breakdown product (pyrolysis oil).
Produced gas from pyrolysis: CO, H2, CH4, CO2.
Syngas from gasifier: CO, H2 ethane, and other gases.
Methanol (intermediate).
Naphtha: feed for plastics.
N-butanol.
Biodiesel production from volatile fatty acids (VFAs) (non-algae based systems).
Products for blending with conventional fuels.
Shrimp food (highest value animal food product).
As one possible technical approach, Fischer-Tropsch reactors could be used to convert
gaseous products (syngas or biogas) to liquid fuels. However, workshop participants noted that
Fischer-Tropsch reactors are difficult to scale down to match the output of a WRRF (generally
less than 100 barrels per day).
Participants also suggested that scale issues might be addressed via a depot system. In
this approach, an intermediate product (e.g., pyrolysis oil) would be produced at the WRRF, then
transported for additional processing at a centralized facility that would accept similar
intermediates from several plants.
As an example of the fuel production scale of these systems, workshop participants cited
projects that produced 1/2 barrel (42-gallon barrel) of syncrude (paraffin and diesel) per wet ton
of dewatered biosolids. Another participant noted that they had found a similar production rate of
60 gallons of syncrude per dry ton of biosolids.
Table 2-8 presents the survey and workshop findings regarding hydrocarbon production
from biosolids. Findings regarding hydrocarbon production from wastewater liquids and biogas
are presented in Section 2.3.3.
2-18
Table 2-8. Higher Hydrocarbon Production from Biosolids.
Respondents: 11
• Very high level of expertise: 2
• High level of expertise: 6
• High level of interest: 3 Majority Consensus Response Contrary Response(s)
How would you characterize the current technology status?
High level of
expertise
Answers widely spread, with respondents indicating technology status as:
• Applied research (2 responses).
• Laboratory testing/validation of alpha prototype (2 responses).
• Lab testing of integrated system (1 response).
• Integrated pilot system demonstrated (2 responses).
Prototype system verified
(1 response).
System incorporated into
commercial design
(1 response).
High level of
interest
Three responses:
• Applied research.
• Critical function studies.
• Prototype system verified.
What are the most pressing research needs for advancing this technology?
High level of
expertise and
interest
• A clear path for conversion of biosolids to hydrocarbons has to be laid
out. For example: biosolids-preconditioning/treatment-pyrolysis-bio-oil
upgrading-hydrogen production from aqueous phase of bio-oil:
hydrotreatment of bio-oil to produce gasoline and diesel.
• What to do with any residual tar, polycyclic aromatic hydrocarbon
(PAH), or other hazardous constituents that become wastes/by-
products.
• Pyrolysis oil conditioning cost and energy to remove moisture, acids,
and other unwanted constituents in the pyrolysis oil (raw bio-oil).
• Improving product quality and downstream processing.
• More test data from a variety of biosolids sources.
• Scale-up beyond bench/lab scale.
• Economics (but not in competition with chemical process industry
production costs).
• Demonstrating high conversion of biosolids energy content to
fuel/evaluating “real-world” net energy balance (energy input vs.
output).
• For HTL: fundamental understanding of how variability in biomass
composition and characteristics influence system performance (cost,
oil yield, quality).
Assessment of Technology Advancements for Future Energy Reduction 2-19
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of
expertise • Integration of know-how from other fields; knowledge base needs
to be built up.
• High CAPEX.
• Water management/separation, extraction of soluble organics in
water phase to fuel/hydrogen.
• Economy of scale issues. Need operating experience and data
showing reliability for full-scale/commercial-scale operations. Co-
location of privately held demonstration plant equipment onsite at
WRRFs.
• Potential to combine biosolids with other biomass to make fuels.
• Reliability.
• Lack of incentive to increase energy production or reduce biosolids
disposal.
• Life-cycle cost analysis to show that the process is more
sustainable than others.
• Management of aqueous phase from HTL (can contain high levels
of toxicity).
Can HTL address
economic/energy issues
with wet sludge?
High level of
interest
Funding.
How economically beneficial do you expect this technology to be?
High level of
expertise
Most likely to be used in new projects and retrofits triggered by “end of
useful life” situations (making adoption slower) (43%).
Comment: Economically favorable, but depends on benchmark. Should
not be compared against the chemical process industry. Look at other
factors, localized availability.
Retrofits of existing
“adequate” equipment could
be cost-effective (28%).
Challenging to be cost-
effective (28%).
High level of
interest
Challenging to be cost-effective (66%). Most likely to be used in new
projects and retrofits
triggered by end of life
(33%).
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of
expertise
Niche market (62%).
Comment: Not a niche market, if we stop talking about it in terms of
wastewater treatment (re-phrased to chemical synthesis).
Transition to industry best
practice (25%).
Potential for almost
universal acceptance (13%).
High level of
interest
Niche market (2 responses).
Transition to best practice
(1 response).
Does this technology have scale considerations or niches? Comments
High level of
expertise
10 mgd (42%)
Comments:
• Opportunity for regional biosolids facility (single biorefinery) to
achieve economies of scale.
• Technology is modular and easily scaled.
100 mgd or greater (29%).
No scale or niche limitations
(29%).
High level of
interest
100 mgd limit (2 responses). 10 mgd (1 response).
If you had to guess, how many years will it take to overcome technical challenges? Comments
High level of
expertise
1-3 years (38%).
3-5 years (38%).
5-10 years (25%).
High level of
interest
Answers split between: 1-3 years, 3-5 years, and more than 10 years .
2-20
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North
American installations)?
High level of
expertise
3-5 years (57%).
1-3 years (29%).
More than 10 years (14%).
High level of
interest
Answers split between 1 year, 3-5 years, 5-10 years .
What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of
expertise
10% reduction or less (37%).
10-25% reduction (25%).
25-50% reduction (14%).
More than 50% reduction
(25%).
High level of
interest
10-25% reduction (2 responses).
10% reduction or less (1 response).
What performance metrics are required to make this technology economically viable?
High level of
expertise • Reduced capital cost.
• Alternative to offsite disposal costs (less than $50/dry ton).
• Percent conversion of biosolids to energy, fuel, or energy
efficiency of the process.
• Production yield (e.g., gallons of hydrocarbon/ton of dry biosolids).
• Recovery of nutrients as well as energy.
• Production kinetics.
• Availability of (appropriate) feedstock.
• Aqueous phase characteristics (including toxicity).
• Positive net present value and low cost per pound of renewable C
utilized (or barrels of petroleum displaced).
High level of
interest • Cost of disposal vs. energy usage/production.
2.3.3 Higher Hydrocarbons from Biogas or Bioliquids
Similar to the previous topic, this technology area includes a wide range of processes in
various stages of development. In the case of biogas, the objective is to produce an upgraded fuel
or chemical product with higher value than the biogas itself.
Technologies to convert biogas to liquid hydrocarbons are similar to technologies being
investigated for stranded gas outputs in oil fields, and include dry reforming using CO2.
Workshop participants also noted that biological processes could be used to convert biogas
methane to methanol or butanol, with a significant positive impact on GHGs from replacing
methanol feeds in BNR processes.
In lieu of hydrocarbons, a potential product stream is bioplastics. For example, DOE has
provided Small Business Innovation Research (SBIR) funding for Mango Materials, a bioplastics
startup from Stanford University. Its process feeds biogas to methanotropes, cycling the process
to promote polyhydroxyalkanoate (PHA) accumulation (up to 50% of cell mass).
Table 2-9 summarizes survey findings regarding higher hydrocarbon production from
biogas or bioliquids.
Assessment of Technology Advancements for Future Energy Reduction 2-21
Table 2-9. Higher Hydrocarbon Production from Biogas or Bioliquids.
Respondents: 5
• Very high level of expertise: 2
• High level of expertise: 2
• High level of interest: 1 Majority Consensus Response Contrary Response(s)
How would you characterize the current technology status?
High level of
expertise
Integrated pilot system (2 responses).
Comment: proven, but not in wastewater context.
System incorporated into
commercial design
(1 response).
System proven and ready for
full commercial deployment
(1 response).
High level of
interest
System incorporated in commercial design/pre-commercial
demonstration.
What are the most pressing research needs for advancing this technology?
High level of
expertise • None, reformation technology well understood.
• Energy analysis, energy integration of all unit operations (drying,
gasification, conversion to liquids).
• By-product yields.
• Cost-effective small-scale sulfur removal.
• Feedstock quality, quantity, and availability.
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of
expertise • Extremely expensive and large scale.
• Operational complexity.
• Integration of know-how from other fields; knowledge base needs
to be built up.
• Demonstration at commercial scale, co-location of privately held
plant equipment onsite at WRRFs.
High level of
interest • Benefit-cost analysis.
How economically beneficial do you expect this technology to be?
High level of
expertise
Most likely to be used in new projects and retrofits triggered by “end of
useful life” situations (making adoption slower) (2 responses).
Comment: Economically favorable, but depends upon benchmark.
Should not be compared with chemical process industry production
costs. Look at other factors, including benefits of localized feedstock
and product availability.
Retrofits of existing
“adequate” equipment could
be cost-effective (1 response).
Challenging to be cost-
effective (1 response).
High level of
interest
Challenging to be cost-effective (1 response).
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of
expertise
Niche market (3 responses). Transition to industry best
practice (1 response).
Not a niche market, if we stop
talking about it in terms of
wastewater treatment (re-
phrased to chemical
synthesis).
High level of
interest
Niche market (1 response).
2-22
Respondents: 5
• Very high level of expertise: 2
• High level of expertise: 2
• High level of interest: 1 Majority Consensus Response Contrary Response(s)
Does this technology have scale considerations or niches? Comments
High level of
expertise
10 mgd (2 responses).
No scale or niche limitations (2 responses).
Comment: aggregation required for economies of scale
Order of magnitude above
WWRF size.
High level of
interest
100 mgd (1 response).
If you had to guess, how many years will it take to overcome technical challenges? Comments
High level of
expertise
1-3 years (2 responses).
5-10 years (2 responses).
High level of
interest
More than 10 years.
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North
American installations)?
High level of
expertise
1-3 years (3 responses). 3-5 years (1 response).
High level of
interest
3-5 years (1 response).
What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of
expertise
25-50% reduction (2 responses).
Comments: enables production of value-added fuels.
10% reduction or less
(1 response).
More than 50% reduction
(1 response).
High level of
interest
10% or less reduction.
What performance metrics are required to make this technology economically viable?
High level of
expertise
Low temperature/low cost catalyst.
Conversion of carbon in organics to commercially viable liquid
transportation fuel, e.g., diesel that meets low sulfur highway specs.
End use needs to be identified before going down this pathway.
Assessment of Technology Advancements for Future Energy Reduction 2-23
2.3.4 Enhanced Methane Production from Anaerobic Digestion
This topic area is intended to focus on potential methods other than sludge pretreatment
(Section 2.2.5) and co-digestion (Section 2.3.5) for increasing methane production from
anaerobic digestion. Table 2-10 summarizes the approaches mentioned by survey respondents.
Note: Responses below are grouped by estimated impact on energy production, with technical
challenges noted. Some approaches are repeated if respondents had differing estimates of the
increased energy production potential.
In addition to the specific digestion approaches listed below, one respondent viewed the
question in the context of a plant as a whole. Energy production from digestion is sometimes
limited by the need to reduce primary clarification capture in order to support a BNR process:
“We need to reduce the carbon demand for N removal to enable the use of
primary settling tanks (no longer existing in many plants to supply more COD to support
N removal). In addition to the mainstream anammox process, N removal via nitrite
(nitritation+denitritation) should be implemented.”
Workshop attendees also noted several other factors that are impacting the enhancement
of methane recovery from wastewater systems. These include:
Regulatory and incentive barriers (i.e., lack of mandates).
A general lack of cooperation between utilities to promote additional energy generation.
Beyond the regulatory barriers identified, additional work is needed to better define
systems and operations practices that maximize the benefits of biogas generation. These
knowledge gaps included:
Better definition of the acid/gas process.
Improved understanding of how feeding strategies impact biogas generation.
Identification of best-in-class operations standards and practices to serve as industry models.
Further definition of the microbial communities involved in digestion.
While significant improvements in methane generation from WRRFs have been made,
further development is needed to maximize the potential of the systems.
2-24
Table 2-10. Enhanced Methane Production from Anaerobic Digestion.
Respondents: 12
• Very high level of expertise: 2
• High level of expertise: 7
• High level of interest: 3 Majority Consensus Response
What techniques are you pursuing or tracking regarding enhanced methane production from anaerobic digestion (other than
pretreatment and co-digestion)?
What is the expected increase in energy production?
What technical challenges apply to these techniques?
~10% increase In energy production • Waste activated sludge anaerobic contact (WASAC): Receives WAS and a
fraction of carbon directed away from activated sludge,
<30-minute contact time, then anaerobic digestion. 10-30% enhanced biogas
production at pilot scale.
• Acid-gas digestion: effective only on primary sludge.
• TPAD: high cost of implementation.
10-25% increase in energy
production
• Phased digestion: odor suppression.
• AnMBRs: membrane fouling and sophistication of operation.
• Improving hydrolysis: understanding the science of what limits hydrolysis.
• Post-digestion thermal hydrolysis: numerous technical challenges.
• Bioaugmentation: additional basic research required.
• Microbial resource management: additional research required.
• Trace nutrient addition for methane maximization: applied and basic research
and demonstration required.
• Acid-gas digestion: applied and basic research and demonstration required.
• Pilot anaerobic digestion at varying loading rates: time required and
complexity in optimizing the system.
• Recuperative thickening: energy consumption, additional process units,
complex operations.
25-50% increase • Methane potential testing for VS and COD fractions of FOG and food waste:
sample collection, process conditions (mixing): correlation between lab and
full-scale without side-by-side systems.
• Catalytic augmentation, microbial gene manipulation to intensify metabolic
pathways.
Assessment of Technology Advancements for Future Energy Reduction 2-25
2.3.5 Optimizing Co-Digestion of Food Wastes
Although use of food wastes for co-digestion has increased dramatically in recent years,
the industry’s understanding of the process is still evolving. Table 2-11 considers new methods
for optimizing co-digestion of various waste streams, including commercial, industrial, and
ideally residential sources.
While the practice of co-digestion is maturing within the wastewater industry, there are
still several challenges to its implementation and realization of ultimate benefit. Some of these
challenges are technical while others are programmatic and logistical:
Improved materials characterization techniques for rapid characterization and process model
input.
Improved C fractionation to better define the synergistic effects of food waste co-digestion.
Identification of non-energy uses for food waste constituents (proteins, lipids,
carbohydrates).
Adoption of separation practices by communities will increase program viability.
Reductions in the variability in the regulatory barriers for interconnection between the
wastewater plant and power utilities.
Improved strategies for N diversion to agriculture for fertilizer use.
Development of more comprehensive and accurate business models demonstrating the value
of a program.
2-26
Table 2-11. Food Waste Co-Digestion.
Respondents: 14
• Very high level of expertise: 3
• High level of expertise: 7
• High level of interest: 3 Majority Consensus Response Contrary Response(s)
What types of new methods for optimizing co-digestion of food waste are you tracking?
High level of expertise • Digester capacity optimization and control.
• Risk management.
• Materials characterization.
• Impact and fate of materials during digestion.
• Process control.
• Stoichiometry.
• Integration of digestion with microbial electrolysis.
• Pretreatment (thermal hydrolysis).
• Food waste pre-processing .
• Recuperative thickening, high solids digestion.
• Optimization of materials blends.
• Microbial communities.
High level of interest Interested parties were tracking:
• Leather tanning waste.
• Materials composition and feed rates.
How are these new methods superior to existing systems?
High level of expertise The improvements associated with the research being
tracked included:
• A reduction in risk and optimization of the economic
outcomes.
• Improved characterization will allow for more stable
operation and increased loadings, and reduce the risk
of upsets.
• Coupling digestion with microbial electrolysis cells
(MECs) could produce hydrogen (a more valuable fuel),
provide reductions in effluent BOD, and high recovery
rates of energy from wastewater solids.
• Improvements in pre-processing technologies can
provide cleaner/less difficult to manage substrate for
digestion, reducing contamination. Potential for
improving the digestibility of the sludge and making it
compatible with municipal anaerobic digesters.
• Recuperative thickening can improve the loading rate of
the digester, allowing for more food waste to be
processed in the same tankage.
• Optimized blending may improve overall energy yield
per unit volume of digester.
High level of interest • Leather tanning waste, could shift a problem waste
material to a commodity opportunity.
Assessment of Technology Advancements for Future Energy Reduction 2-27
Respondents: 14
• Very high level of expertise: 3
• High level of expertise: 7
• High level of interest: 3 Majority Consensus Response Contrary Response(s)
What are the current technical challenges with these new methods?
High level of expertise A majority of respondents indicated some level of technical
challenge associated with food waste co-digestion, including:
• Standardization of methodologies.
• Integration of materials characterization with
operations.
• Optimization of the digestion with the MEC process to
achieve higher energy recovery.
• Slow adoption and drivers are limiting a demonstrated
concept.
• Identification of waste sources.
• Pilot studies, good metrics to allow for comparison.
• Lack of capital resources.
• A general gap in knowledge surrounding the microbial
structure, feedstock digested, and methane yield from
the process.
A counter opinion on
the subject matter
indicated that no
current technical
challenges are
associated with food
waste co-digestion.
High level of interest The technical challenges identified included:
• Process inhibition from the digestion of tannery waste.
• Supply chain, reliability and control of materials, and
source separation.
Are you aware of any pilot or new installations of these new methods?
High level of expertise and
interest
The ongoing research on specific topics was identified as
follows:
• Process control and stoichiometry: DC Water, Bucknell
University, Spain.
• Digestion with MEC: no ongoing research.
• Materials pre-processing: 11 full-scale demonstration
projects in Europe.
• Recuperative thickening: Victorville, CA.
• High solids digestion: Europe and new facilities to be
installed in the U.S..
• Co-digestion operations listed in survey: Deer Island
WWTP, DWU has a facility under construction. LA
County is doing a co-digestion study at one plant.
• Pre-processing operations: ClearCove, Ithaca, NY;
Grind2Energy, multiple facilities; Salsnes and others,
multiple facilities.
• High solids digestion: Oshkosh, WI.
• OFMSW digestion: San Jose, CA and Toronto, Canada.
• Pre-processed food waste: LA County Joint WPCP and
Waste Management (20,000 gpd).
• Tannery waste co-digestion: Florence, Italy.
2-28
Respondents: 14
• Very high level of expertise: 3
• High level of expertise: 7
• High level of interest: 3 Majority Consensus Response Contrary Response(s)
Additional Comments
High level of expertise Additional comments from survey participants included:
• This is the largest energy opportunity for most WRRFs
because food waste in municipal solid waste is
generally the largest source of organic feedstock; it can
provide 5-10% of California’s energy demand, for
example.
• Optimizing feedstock blends. University of Michigan has
simulated functional operating space of co-digestion
systems, considering which design factors are most
predictive of performance and which factors the system
is most sensitive to.
• Food waste is a moving target, because as we focus on
it people tend to stop wasting so much food in the first
place. Movement seen toward eating less and wasting
less, saving C footprint of food production and
transportation chain.
Assessment of Technology Advancements for Future Energy Reduction 2-29
2.3.6 Membrane Production and Capture of Hydrogen from Wastewater
Hydrogen is extracted by contacting wastewater with a membrane laden with hydrogen-
generating bacteria. As the bacteria metabolize organic matter, hydrogen is passed into hollow fibers
for removal and can be utilized by fuel cells for energy production. The bacterial process removes
organic contaminants, reducing aeration demands. The system is modular and can be altered to fit
many liquid waste streams including industrial, agricultural, and sanitary waste. Table 2-12 presents
the survey findings regarding membrane production and capture of hydrogen from wastewater.
Table 2-12. Membrane Production of Hydrogen from Wastewater.
Respondents: 3
• Very high level of expertise: 1
• High level of expertise: 2 Majority Consensus Response How would you characterize the current technology status?
High level of expertise Basic research (1 response).
Applied research (1 response).
Critical function (1 response).
What are the most pressing research needs for advancing this technology?
High level of expertise • Fundamental research in bioelectrochemical systems (BESs).
• Using microbial electrolysis for hydrogen production.
• This technology has been laboratory-tested using some real wastewaters. The next
step is to optimize materials with scale-up in mind.
Comment: Oak Ridge has used biorefinery wastewater to generate hydrogen at higher
than 50% efficiency from the organic content in wastewater.
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of expertise • Cost of membranes.
• Life of materials.
• Maintaining high performance of system over long term (months or more).
• Funding for optimization and scale-up phase. This type of funding is challenging to
get from many funding agencies (NSF, etc.), but is critical if the technology is going
to be demonstrated as viable, enabling adoption. In addition, an early adopter is
critical to push and champion this technology.
How economically beneficial do you expect this technology to be?
High level of expertise It will be challenging to make this technology economically beneficial (1 response).
Most likely to be used in new projects and retrofits triggered by “end of useful life”
situations (making adoption slower) (1 responses).
Retrofits of existing “adequate” equipment could be cost-effective.
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of expertise Niche market (2 responses).
Potential for almost universal acceptance (1 response).
Does this technology have scale considerations or niches?
High level of expertise No scale or limitations (3 responses), but high-strength wastewater such as industrial or
food streams preferred.
If you had to guess, how many years will it take to overcome technical challenges?
High level of expertise 1-3 years (2 responses).
5-10 years (1 response).
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North American
installations)?
High level of expertise 1-3 years (2 responses).
More than 10 years (1 response).
2-30
Respondents: 3
• Very high level of expertise: 1
• High level of expertise: 2 Majority Consensus Response What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of expertise More than 50% reduction (3 responses).
What performance metrics are required to make this technology economically viable?
High level of expertise Hydrogen productivity > 15 L H2/L reactor-day.
Current density > 20 A/m2.
Energy efficiency > 50%.
Material costs (membrane costs) and/or longevity.
Assessment of Technology Advancements for Future Energy Reduction 2-31
2.3.7 Pyrolysis/Gasification of Biosolids
This topic area included potential future enhancements in thermal treatment of biosolids
(pyrolysis and gasification), with an emphasis on how to improve energy generation from these
processes. Pyrolysis and gasification can be used to process either raw or digested solids.
Gasification and pyrolysis are closely related technologies, with the key differentiator
being the presence or absence of oxygen and the nature of the products produced. Pyrolysis
operates at a temperature of over 300°C, in the absence of oxygen and with limited water.
Pyrolysis produces oil, which can be refined or digested as an energy source. Under certain
operating conditions, syngas can also be produced. The solids residual is biochar, which has been
proposed for use as an agricultural amendment because of its water-retention capacity and
phosphate content.
Gasification operates under sub-stoichiometric conditions, with small amounts of oxygen
and steam added to control gas production. The solid residual produced via gasification is ash.
Biogas (syngas) is produced, but in recent projects the biogas is used primarily to dry the feed
sludge, leaving no surplus gas available to generate additional energy. Workshop participants
suggested that increased thermal heat recovery could be used to improve the energy balance.
Workshop participants believed that both technologies held promise for future
development. The advantage of one approach over the other would depend on which fuel and
residual products are best suited for a given project application. Participants stated that there
would be value to a separate workshop focused on overcoming barriers to wider deployment of
this technology.
Survey and workshop findings regarding gasification and pyrolysis of biosolids are
summarized in Table 2-13.
Table 2-13. Gasification and Pyrolysis.
Respondents: 10
• Very high level of expertise: 3
• High level of expertise: 5
• High level of interest: 2 Majority Consensus Response Contrary Response(s)
How would you characterize the current technology status?
High level of expertise Answers widely spread; majority response: system
incorporated into commercial design (37%).
Comments: pilot pyrolyzer at Marquette and full-
scale demonstration at Encina, CA.
Applied research (12%).
Lab testing of alpha prototype (12%).
Prototype verified (12%).
Integrated pilot system demonstrated
(12%).
System proven and ready for
commercial deployment (12%).
High level of interest Lab testing of integrated system (1 response) .
Prototype system verified (1 response).
2-32
Respondents: 10
• Very high level of expertise: 3
• High level of expertise: 5
• High level of interest: 2 Majority Consensus Response Contrary Response(s)
What are the most pressing research needs for advancing this technology?
High level of expertise • Downstream processing/What to do with bio-
oil/tar.
• Consistency of feed.
• Robustness/reliability.
• Full-scale demonstration.
• Improving cost structure/cost-effective
improvement in energy balance (wet sludge).
• Sulfur in biogas, other sulfur management
issues.
High level of interest • Residuals characterization and beneficial use
pathway.
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of expertise • High CAPEX.
• Robustness relative to incineration.
• Water content.
• Lack of incentive to reduce biosolids disposal
cost or to reuse solids in soils .
• Lack of regulatory driver for increasing energy
recovery, reducing GHG.
• Risk aversion.
• Issues with subsequent processes can be
more problematic that thermal reactor itself.
HTL to address economic/energy issues
with wet sludge?
High level of interest • High CAPEX.
• Siting.
How economically beneficial do you expect this technology to be?
High level of expertise Most likely to be used in new projects and retrofits
triggered by “end of useful life” situations (making
adoption slower) (50%).
Retrofits of existing “adequate”
equipment could be cost-effective
(35%).
High level of interest Challenging to be cost-effective: best used for
destruction of sludge to reduce digestion and
dewatering costs.
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of expertise Niche market (55%). Transition to industry best practice
(33%).
High level of interest Niche market (one response).
Does this technology have scale considerations or niches?
High level of expertise No scale or niche limitations (50%).
100 mgd or greater (25%).
10 mgd (25%).
High level of interest No scale or niche limitations (1 response).
100 mgd limit (1 response).
Assessment of Technology Advancements for Future Energy Reduction 2-33
Respondents: 10
• Very high level of expertise: 3
• High level of expertise: 5
• High level of interest: 2 Majority Consensus Response Contrary Response(s)
If you had to guess, how many years will it take to overcome technical challenges?
High level of expertise 1-3 years (37%).
3-5 years (37%).
1 year (12%).
5-10 years (12%).
High level of interest 3-5 years (1 response).
5-10 years (1 response).
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North
American installations)?
High level of expertise 1-3 years (50%).
3-5 years (37%).
More than 10 years (12%).
High level of interest 5-10 years (2 responses).
What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of expertise 10-25% reduction (50%).
25-50% reduction (37%).
10% reduction or less (12%).
High level of interest 10-25% reduction (2 responses).
What performance metrics are required to make this technology economically viable?
High level of expertise • Reduced capital cost.
• Solid mass degradation >50%.
• Reduced disposal costs relative to existing
methods.
• Net energy production and GHG reductions.
• Ability to recover phosphorus, metals from
ash, clinker, or production of higher-value
products.
• Reduction of criteria air pollutants, air permits
for engines’ burning point: gas.
High level of interest • Net energy production.
2-34
2.4 Technologies that Combine Efficient Treatment with Energy Recovery
The transformative technologies presented in this section represent a break with current
liquid and solids treatment approaches. On the liquid treatment side, technologies considered
include anaerobic treatment in lieu of aerobic activated sludge technology, using MFCs to
remove organic contaminants, using batteries to remove nitrogen, or algal nutrient removal with
energy harvesting. On the solids side, supercritical wet oxidation for energy production is
reviewed.
2.4.1 Mainstream Anaerobic Treatment
Several approaches have been researched to treat wastewater anaerobically, including but
not limited to AnMBRs, anaerobic fluidized bed membrane bioreactors (AFMBRs), and upflow
anaerobic sludge blanket reactors (UASBs). Some treatment configurations use combinations of
these anaerobic approaches, or combinations that include downstream aerobic systems, in order
to achieve plant performance that meets effluent standards.
Some types of anaerobic systems have been successfully applied to high-strength
industrial wastewater for many years, but researchers are working to configure systems to treat
dilute and colder domestic wastewater, with the goal of generating biogas and dramatically
reducing energy inputs for organic removal. Additional work is needed to further develop the
technology. Primary areas of additional development include:
Management and recovery of dissolved methane.
Treatment/management strategies for ammonia and sulfides.
Integration with other mainstream N removal technologies.
Nutrient recovery from dilute streams (e.g., struvite).
Synergies with microbial electrolysis cells (MECs).
Generation of alternative products (methanol, VFAs).
Economic pretreatment of particulates to improve conversion.
Management of peak and other transient conditions.
Along with additional research, it was noted that increased efforts to disseminate the
advances surrounding this particular unit operation are still needed. Partnerships with utilities to
demonstrate full-scale process efficacy would support the further development and ultimate
commercialization of the process. However, it was noted that gaining regulatory support for the
process would improve the viability of the system. The development of a fully monetized triple-
bottom-line analysis was recommended to demonstrate the full value of the technology.
Table 2-14 summarizes survey and workshop findings regarding anaerobic mainstream
treatment technologies.
Assessment of Technology Advancements for Future Energy Reduction 2-35
Table 2-14. Anaerobic Mainstream Treatment.
Respondents: 15
• Very high level of expertise: 5
• High level of expertise: 9
• High level of interest: 1 Majority Consensus Response Contrary Response(s)
How would you characterize the current technology status?
High level of expertise More than half of the respondents believed that
mainstream anaerobic treatment was at the pilot level with
demonstration in relevant environments (53%). The next
largest group believed it was in the applied research stage,
alpha prototype (15%). It was noted that this technology is
currently used primarily in warmer climates or on
processes with higher-strength wastewater, such as
industrial pretreatment systems.
A small percentage
(15%) indicated the
process is ready for full
commercial design or
deployment.
What are the most pressing research needs for advancing this technology?
High level of expertise The following research needs were identified by the survey
group:
• Integration of N and P removal: anammox may not be
the primary N-removing process because of the
presence of residual VFAs, dissolved methane, and
sulfide.
• Improvements in methane recovery and utilization,
efficiency and cost, soluble methane management
(avoiding GHG release).
• Operation at lower wastewater temperatures and at
lower wastewater strengths.
• Improved effluent through membranes, address
membrane fouling issues, and efficient polishing of
permeate.
• For microbial electrolysis: demonstration of 20 A/m2
in domestic wastewater.
• Demonstration of process in large-scale domestic
wastewater pilot (e.g., Stanford University project) to
verify efficacy of all process elements with highly
instrumented systems, modeling, and integrated
(economic, environmental, energy) analysis.
• Verification of process performance against stringent
permit limits.
• Expansion beyond methane end use with treated
carbon.
2-36
Respondents: 15
• Very high level of expertise: 5
• High level of expertise: 9
• High level of interest: 1 Majority Consensus Response Contrary Response(s)
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of expertise The significant non-technical challenges identified by the survey group included:
• Broad commercial providers.
• Operator training.
• Allowing for deployment in low-temperature and low-wastewater strength systems.
• Regulatory acceptance.
• Impact on biosolids characteristics.
• Lack of pilot studies.
• Long-term performance and scalability.
• Sunk capital investments (e.g., primary clarifiers).
• Cost associated with retrofit from current activated sludge systems.
• Depth and breadth of operating systems and conditions relative to permit limit
demands.
• Improved energy efficiency, especially regarding energy consumption for fouling
mitigation.
• Sustainable way to remove/recover ammonia and nitrogen from AnMBR effluent.
How economically beneficial do you expect this technology to be?
High level of expertise The majority (57%) believed this technology would be
adopted for new systems or “end of useful life” scenarios,
resulting in slower adoption.
Retrofits of existing
“adequate” equipment
could be cost-effective
(43%).
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of expertise A majority of responses had a view of broad applicability of
this technology: universal acceptance (21%) or a transition
to best practices for a majority of plants (42%).
A good number of
respondents indicated
that this is only a niche
technology (36%),
contrary to the majority
opinion.
Does this technology have scale considerations or niches?
High level of expertise The majority believed mainstream anaerobic treatment did
not have any specific scale considerations (71%).
10 mgd (21%).
100 mgd (7%).
If you had to guess, how many years will it take to overcome technical challenges?
High level of expertise The majority responses indicated that 3-10 years of work
will be required to overcome the technical challenges. • 3-5 years (57%).
• 5-10 years: (35%).
1-3 years (7%).
Assessment of Technology Advancements for Future Energy Reduction 2-37
Respondents: 15
• Very high level of expertise: 5
• High level of expertise: 9
• High level of interest: 1 Majority Consensus Response Contrary Response(s)
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North
American installations)?
High level of expertise 5-10 years (43%). 1-3 years (28%).
3-5 years: (28%).
What performance metrics are required to make this technology economically viable?
High level of expertise • Metrics surrounding enabling technologies.
• Sludge and energy balances.
• 1-year membrane cleaning cycle (demonstrated).
• Operating costs ($/MG-treated) and energy demand (kW/MG-
treated).
• Methane recovery rates and GHG inventory impacts (soluble
methane loss).
• Effluent values in line with NPDES permits (BOD, TSS, N, and P
removal rates).
• Sludge production metrics.
• Chemical use data (savings/costs).
• Demonstration of reliable operation.
What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of expertise A large majority of respondents indicated a large savings
on plant energy use with mainstream anaerobic treatment:
>50% savings (72%)
Comments:
• Process could become energy and chemical positive if
wastewater is more concentrated and if coupled with
low energy demanding downstream processes.
• Depends on whether post-process aerobic treatment
is necessary for polishing.
10-25% and
20-50% reduction
(14% each).
2-38
2.4.2 Microbial Fuel Cells
Bioelectrochemical systems (BESs) are electrochemical cells that use electrochemically
active microorganisms as catalysts on one or both electrodes. BESs can be divided into
electricity-producing MFCs and electricity-consuming MECs. Table 2-15 presents survey and
workshop findings regarding MFCs. Findings regarding MECs are presented in Section 2.4.3.
An MFC is a device that generates electricity from bacterial metabolism of organic
matter (which is measured as chemical oxygen demand [COD] in wastewater). During the final
stage of bacterial metabolism, electrons are passed along the cell membrane and deposited onto a
terminal electron acceptor, usually oxygen under aerobic conditions. In an MFC, bacteria
transfer their electrons externally to an anode. Electrons flow from the anode to a positively
charged cathode through an external circuit; this flow of electrons represents an electrical
current. The cathode is exposed to oxygen and protons (H+) that chemically react with the
incoming electrons to form water (U.S. EPA, 2013).
While some have raised low wastewater condition as a barrier to this technology,
researchers attending the workshop noted that they have found good current production at COD
concentrations above 150-200 mg/L. At high organic concentrations (3,000 mg/L), the reactor
goes anaerobic. Therefore, the viable organic concentration range would be well-matched for
COD concentrations found in typical municipal wastewater.
The most likely use for MFCs envisioned by workshop participants was to reduce COD
concentrations prior to secondary treatment, either to reduce aeration or as pretreatment for
anaerobic reactors. In addition to reduced secondary treatment energy, this potential approach
has the advantage of not using a methane pathway, reducing concerns about fugitive methane
emissions and ideally simplifying the electrical generation process.
Table 2-15. Microbial Fuel Cells.
Respondents: 10 • Very high level of expertise: 2 • High level of expertise: 5 • High level of interest: 3 Majority Consensus Response Contrary Response(s)
How would you characterize the current technology status?
High level of expertise Applied research (57%).
Laboratory testing/validation of alpha prototype
(2 responses) (29%).
Lab testing of
integrated/semi-integrated
system (1 response).
High level of interest Laboratory testing/validation of alpha prototype
components (2 responses).
Critical function: validate analytical predictions of
separate elements (1 response).
What are the most pressing research needs for advancing this technology? High level of expertise • Current efficiency (mainly electrodes).
• Manufacturing of cathodes (specialized
design; manufacturers unwilling to make
custom designs).
• Application to real wastewater.
• Scale up, especially anode design (goal of
1 gpm unit for next demonstration).
• Improving long-term operation.
• Finding low-voltage uses.
• Solids management; biomass yield is midway
between conventional aerobic and anaerobic
yield rates.
MFC has proved to be
unsuitable for energy
recovery from wastewater,
but may have some niche
applications.
MFC technology has been
stuck on the bench for years.
Microbial electrolysis rather
than microbial fuel cells will
provide the economic benefits.
High level of interest Understanding microbial populations and metabolic
pathways; electrochemical pathways.
Assessment of Technology Advancements for Future Energy Reduction 2-39
Respondents: 10 • Very high level of expertise: 2 • High level of expertise: 5 • High level of interest: 3 Majority Consensus Response Contrary Response(s)
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of expertise • Cost of equipment.
• Understanding the effect of process.
parameters over long term.
• Demonstration at pilot scale.
• Downstream nutrient removal required.
High level of interest • Cost: electrode pricing.
• Treat in the same footprint as current aerobic
systems.
How economically beneficial do you expect this technology to be?
High level of expertise Challenging to be cost-effective (57%).
Comment: MFC technology can perform well, but
can the energy savings offset the cost within a
reasonable time frame? This will be a challenge
because technology is currently costly and energy is
cheap.
Retrofits of existing
“adequate” equipment could
be cost-effective (29%).
Most likely used in new
projects or triggered by
retrofits (1 response).
High level of interest Most likely used in new projects or triggered by
retrofits (2 responses).
Challenging to be cost-effective (1 response).
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of expertise Niche market (71%). Transition to industry best
practice at majority of plants
(29%).
High level of interest Niche market (2 responses) .
Transition to industry best practice at majority of
plants (1 response).
Does this technology have scale considerations or niches? Comments
High level of expertise No scale or niche limitations (71%).
Comment: influent strength more likely to be a
consideration than plant size.
10 mgd (29%).
High level of interest
If you had to guess, how many years will it take to overcome technical challenges? Comments
High level of expertise 1-3 years (2 responses).
5-10 years (2 responses).
1-3 years (2 responses).
More than 10 years
(1 response).
High level of interest 5-10 years (2 responses). More than 10 years
(1 response).
2-40
Respondents: 10 • Very high level of expertise: 2 • High level of expertise: 5 • High level of interest: 3 Majority Consensus Response Contrary Response(s)
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North
American installations)?
High level of expertise 5-10 years (3 responses).
1-3 years (1 response).
3-5 years (1 response).
More than 10 years
(1 response).
High level of interest 3-5 years (2 responses), more than 10 years
(1 response).
What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of expertise More than 50% reduction (4 responses). 10% reduction or less
(1 response).
10-25% reduction
(1 response).
High level of interest 25-50% reduction (2 responses), 10-25% reduction
(1 response).
What performance metrics are required to make this technology economically viable?
High level of expertise • Current >25 A/m2
• CAPEX <$500/m2
• Electrodes that cost less than $100-$150/m2 and that are easy to
manufacture.
Comment: A current density of > 20 A/m2 has been demonstrated at
laboratory scale. This is close to being sufficient for commercial consideration.
Further understanding of performance stability over long term is necessary.
Following that, pilot-scale studies will be needed to demonstrate performance at
larger scale.
High level of interest • Ability to meet NPDES permit limits including N and P. If not, what follow-on
treatment is required?
• Cost of treatment per MG treated (including pretreatment and polishing steps).
• Solids generation compared to current practices.
• Energy generated/consumed per 1 MG treated.
Assessment of Technology Advancements for Future Energy Reduction 2-41
2.4.3 Microbial Electrolysis Cells
Many possible wastewater related applications for BESs have been developed recently.
Microorganisms can be used to catalyze cathodic reactions (at biocathodes), such as oxygen
reduction to water, proton reduction to hydrogen, nitrate reduction to nitrogen gas, and
bicarbonate reduction to methane (Sleutels et al., 2012). Other applications include hydrogen
peroxide production, desalination (Logan, 2010), and recovery of ammonia. Many of the new
applications for cathode reactions need additional energy input, which is determined by
thermodynamics of the overall reaction. Table 2-16 summarizes survey findings regarding
MECs.
Table 2-16. Microbial Electrolysis Cells.
Respondents: 5
• Very high level of expertise: 2
• High level of expertise: 2
• High level of interest: 1 Majority Consensus Response Contrary Response(s)
How would you characterize the current technology status?
High level of expertise Laboratory testing/validation of alpha prototype
(2 responses).
Applied research
(1 response).
Lab testing of
integrated/semi-integrated
system (1 response).
High level of interest Applied research (1 response).
What are the most pressing research needs for advancing this technology?
High level of expertise • Current efficiency (mainly electrodes).
• Continuous flow tests with domestic wastewater
(performance metrics have been demonstrated
with biorefinery wastewater).
Need to find niche
applications; H2 production
only will not get this
technology anywhere.
High level of interest Understanding microbial populations; catalysts.
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of expertise • Acceptance of new technology.
• Maintaining high performance over long term.
• Identifying need for products.
High level of interest • Cost.
How economically beneficial do you expect this technology to be?
High level of expertise Most likely used in new projects or triggered by
retrofits (2 responses).
Retrofits of existing
“adequate” equipment
could be cost-effective
(1 response).
High level of interest Challenging to be cost-effective (1 response).
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of expertise Niche market (2 responses). Transition to industry best
practice at majority of
plants (1 response).
High level of interest Niche market (1 responses)
Does this technology have scale considerations or niches? Comments
High level of expertise and interest No scale or niche limitations (all responses).
2-42
Respondents: 5
• Very high level of expertise: 2
• High level of expertise: 2
• High level of interest: 1 Majority Consensus Response Contrary Response(s)
If you had to guess, how many years will it take to overcome technical challenges? Comments
High level of expertise 1-3 years (1 response).
3-5 years (1 response).
5-10 years (1 response).
High level of interest More than 10 years (1 response). More than 10 years
(1 response).
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North
American installations)?
High level of expertise 1-3 years (1 response).
3-5 years (1 response).
5-10 years (1 response).
High level of interest 3-5 years (1 response).
What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of expertise More than 50% reduction (2 responses). 10% reduction or less
(1 response).
High level of interest 10-25% reduction (1 response).
What performance metrics are required to make this technology economically viable?
High level of expertise • > 15 L H2/L anode-day .
• > 20 A/m2 > 50% energy efficiency.
• > 70% cathode potential efficiency.
• > 80% anode coulombic efficiency.
Assessment of Technology Advancements for Future Energy Reduction 2-43
2.4.4 Supercritical/Subcritical Water Oxidation for Sludge Treatment and Energy
As temperature and pressure increase, water approaches what is known as the “critical
point” (≥374.2°C and 22.1 megapascals [MPa]), above which water becomes “supercritical.”
Supercritical water can be used as a solvation media for rapid gasification and destruction of raw
or digested sludge, without pre-thickening or dewatering. Pure oxygen is fed to the reactor for
oxidation and COD is converted to CO2 within one minute. The effluent is a slurry of inorganic
ash in a water phase. Heat energy can be recovered directly by heat exchange in the reactor, or
from effluent leaving the reactor (Kalogo, 2008).
Table 2-17 summarizes the survey findings regarding supercritical/subcritical water
oxidation for sludge treatment and energy.
Table 2-17. Supercritical/Subcritical Water Oxidation for Sludge Treatment.
Respondents: 3
• Very high level of expertise: 0
• High level of expertise: 2
• High level of interest: 1 Majority Consensus Response
How would you characterize the current technology status?
High level of expertise System incorporated in commercial design: pre-commercial demonstration
(1 response).
System proven and ready for full commercial deployment (1 response).
High level of interest Laboratory testing/validation of alpha prototype (1 responses).
What are the most pressing research needs for advancing this technology?
High level of expertise Full-scale demonstration and validation of performance and costs.
High level of interest Pilot-scale demonstration.
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of interest • Reluctance to adopt an unfamiliar technology.
• Fear of change.
• Initial capital cost.
How economically beneficial do you expect this technology to be?
High level of expertise Retrofits of existing “adequate” equipment could be cost-effective (1 response).
Challenging to be cost-effective (1 response).
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of expertise and interest
Niche market (2 responses).
Potential for almost universal acceptance (1 response).
Does this technology have scale considerations or niches?
High level of expertise and interest 10 mgd (1 response).
No scale or niche limitations (1 response).
If you had to guess, how many years will it take to overcome technical challenges? Comments
High level of expertise and interest 1 year (2 responses).
3-5 years (1 response).
Following technical maturity and proof of concept, how long will commercialization or adoption take (e.g., at least two North
American installations)?
High level of expertise 1 year (1 response).
3-5 years (1 response).
High level of interest 5-10 years (1 response).
2-44
Respondents: 3
• Very high level of expertise: 0
• High level of expertise: 2
• High level of interest: 1 Majority Consensus Response
What is your best estimate of the potential impact of this technology on overall plant energy use?
High level of expertise and interest 10% reduction or less (1 response).
More than 50% reduction (2 responses).
What performance metrics are required to make this technology economically viable?
High level of expertise • Demonstrated reliable operation at full-scale.
• Efficiency reasonably consistent with predictions.
Comment: “If this works, it might be the most transformative technology for
solids processing our industry has.”
Assessment of Technology Advancements for Future Energy Reduction 2-45
2.4.5 Integration of Algal Treatment for BNR with Algal Energy Production
As an alternative or adjunct to current BNR strategies, the nutrients contained within
wastewater may be removed via the growth of aquatic plants such as algae, microalgae, and
duckweed. Because various algae have evolved to uptake nutrients from water bodies with low
nutrient concentrations, they have the potential to polish effluent nutrient concentrations to very
low levels.
As one survey respondent noted, algae is the only approach to nutrient management that
has the potential to achieve energy-positive nutrient recovery. Algae also have the potential to
meet more stringent effluent nutrient limits than chemotrophic bacterial systems (e.g., enhanced
biological phosphorus removal [EBPR], nitrification/denitrification) can.
Mixed algae and bacterial cultures can be used to reduce reliance on sunlight, because a
portion of the culture can use COD for energy.
A key aspect of the viability of this technology is realizing value from the algae.
Workshop participants noted various views of how value could be obtained from future algae
processes:
High-value products. Algae can be used as a feedstock for production of high-value products
such as fish food or nutricuticals (nutrients, dietary supplements), improving the financial
viability algae processes relative to fuel production via algae lipids.
Increased carbon for energy production. Compared to conventional aerobic processes, algae
processes do not “lose” carbon to biological respiration (CO2). Furthermore, algae processes
harvest solar energy used in photosynthesis, growing additional algal mass. The net result is a
significant increase in the amount of organic material available for downstream energy
production (e.g., biofuel production, methane generation through anaerobic digestion).
Carbon credits. Because algae treatment has the potential to significantly reduce aeration
energy inputs and increase energy production, it could have potential future value for its
carbon-reducing attributes.
Table 2-18 summarizes survey and workshop findings regarding current areas of algae
research.
Table 2-18. Integration of Algal Treatment and Harvesting.
Respondents: 7
• Very high level of expertise: 3
• High level of expertise: 3
• High level of interest: 1
Responses
What types of new methods for optimizing algal treatment are you tracking?
High level of expertise • Artificial light, natural light, light collectors (e.g., top of digesters).
• Research on oxygenic biogranules that are a mixture of microalgae
and bacteria growing in granules.
• Lab systems for nutrient removal.
• Mixotrophic algal cultivation.
• Clearas Water Recovery (packaged/modular system to recover
nutrients).
• Removing N and P from secondary effluent and sidestreams.
• Treating primary influent.
High level of interest • Biofilm high-rate photobioreactors.
2-46
Respondents: 7
• Very high level of expertise: 3
• High level of expertise: 3
• High level of interest: 1 Responses
How are these new methods superior to existing systems?
High level of expertise • Allows for aeration-free wastewater treatment and nutrient
removal.
• Conserves 100% of chemical energy in wastewater in the form of
biofeedstock (harvested algae or biogranules). Produces large
amounts of biomass, but has potential for biofuel production via
downstream energy production processes (methane production via
anaerobic digestion, oil production via HTL, bioethanol production,
biodiesel production, etc.). Alternatively, algae are a very good and
widely used soil amendment.
• For biogranule approach: the biomass separates well from water
(10-minute settling), allowing high flow-through wastewater
treatment, such as hydraulic retention time (HRT) < 0.5 day.
• For mixotrophic cultivation: In contrast to photoautotrophic strains,
mixotrophic strains offer BOD, N, and P removal in one step.
• For Clearas: Vendor claims that algae oxygenates water,
potentially reducing need for aeration if recycled to secondaries or
re-aeration before discharge to water body.
High level of interest • For biofilm high-rate photobioreactors: Smaller footprint. Not as
weather-dependent.
What are the current technical challenges with these new methods?
High level of expertise • Land area, especially for large facilities: may be best suited for
rural sites. Biomass growth rates, long detention time.
• Efficient recovery (harvesting) of algae. Need cost-effective DAF or
membrane separation of algae, or gravity settling process
improvements such as bioflocculation or granules.
• Control of biomass types (speciation) and quantity in reactors.
• Finding uses of algae after separation (e.g., digestion of algae).
• Making life-cycle costs competitive with conventional alternatives.
This analysis could also look at the cost per pound of carbon
harvested relative to other C reduction approaches.
• For oxygenic biogranules: finding and controlling optimum size of
granules, which will allow maintenance of effective treatment and
energy: solids separation, production of high-quality effluent,
production of biofuels.
• Growing algae 24x7.
• Growing algae in cold climates, or variety of wastewaters.
Potential development of phototrophic bacteria as a competing
process.
Comment: We simply do not have enough of an understanding to
design such systems today and know that they will work.
High level of interest The technical challenges identified included:
• Nutrients occur in too small of concentrations to make process
economical at large scale.
Assessment of Technology Advancements for Future Energy Reduction 2-47
Respondents: 7
• Very high level of expertise: 3
• High level of expertise: 3
• High level of interest: 1 Responses
Are you aware of any pilot or new installations of these new methods?
High level of expertise or interest Ongoing research and pilot projects were identified in the survey and
workshop as follows:
• Europe, Australia (Melbourne).
• Pending at Chicago (MWRDGC).
• First oxygenic biogranules pilot at Amherst WRRF, summer 2015.
The pilot will run through winter in Massachusetts; increasing the
SRT of the granule process is expected to help overcome
challenges associated with reduced sunlight and low water
temperature during winter. Granules are half bacteria and half
algae.
• Upper Blackstone Water Pollution Abatement District (Worcester,
MA) large-scale pilot (Clearas). This system uses specialized LEDs
for nighttime illumination, at reduced costs because of off-peak
power rates.
• There are “Algaewheel” systems (an attached growth systems) at
various small installations (e.g., Hamilton, VA), and the Iowa State
attached growth system may be tested at Metropolitan Water
Reclamation District of Greater Chicago.
• NYC DEP pilot-tested an algal turf racetrack system for centrate
treatment, but found that it was not suitable for bulk N removal.
• New Mexico State University is testing a closed algae reactor using
algae culture gathered from hot spring environments treating
primary effluent. The specialized algae culture withstands warm
environments in a closed reactor and the closed reactor improves
process stability by maintaining consistent cultures.
• Cal Poly is conducting research at the San Luis Obispo Water
Reclamation Facility, including biofuel production. This project is
operating a 7-acre algal raceway facility with drying beds, with a
focus on increasing algae production.
2-48
2.4.6 Thermally Regenerative Ammonia-Based Batteries
Low-grade waste heat is an artifact of many energy-generating methods, including CHP
heat recovery, which sometimes generates more heat than the wastewater plant and digestion
system can use. Thermally regenerated ammonia-based batteries (TRABs) are being developed
as a means to utilize low-grade waste heat for power production.
TRABs consist of copper electrodes with ammonia added only to the anolyte – the
electrolyte surrounding the anode. This type of battery would be useless as a constant source of
electricity if the reaction were not regenerative. Using low-grade waste heat from an outside
source, the researchers distill ammonia from the effluent left in the battery anolyte and then
recharge it into the original cathode chamber of the battery.
In preliminary research, a power density of about 60 watts per square meter was
produced over multiple cycles, which is six to 10 times higher than the power density produced
by other liquid-based thermal-electric energy conversion systems (Logan, Messer, 2014).
Table 2-19 summarizes the TRAB survey responses from the one survey respondent with
expertise in this area.
Table 2-19. Thermally Regenerative Ammonia-Based Batteries.
Respondents: 1
Very high level of expertise: 1 Response
How would you characterize the current technology status?
High level of expertise Basic research: basic principles are observed (1 response).
What are the most pressing research needs for advancing this technology?
High level of expertise Understanding how to optimize the chemistry.
What are the most significant non-technical hurdles to commercialization or widespread adoption?
High level of expertise None listed.
How economically beneficial do you expect this technology to be?
High level of expertise Most likely to be used in new projects and retrofits triggered by “end of useful life”
situations (making adoption slower) (1 response).
How would you characterize the applicability of this technology (economics aside, just looking at plant characteristics)?
High level of expertise Transition to best practice at majority of plants (1 response).
Does this technology have scale considerations or niches?
High level of expertise No scale or niche limitations (1 response).
If you had to guess, how many years will it take to overcome technical challenges?
High level of expertise 5-10 years (1 response).
Following technical maturity and proof of concept, how long will commercialization or adoption take
(e.g., at least two North American installations)?
High level of expertise 5-10 years (1 response).
Assessment of Technology Advancements for Future Energy Reduction 2-49
2.5 Other Technologies
Several workshop participants strongly recommended that membrane biofilm reactors
(MBfRs) or membrane aerated biofilm reactors (MABR) be included as an important technology
with significant potential to reduce energy use. MBfRs use pressurized membranes to supply a
gaseous substrate to a biofilm formed on the membrane’s exterior. MBfRs are suited for various
treatment applications, including the removal of C and N when oxygen is supplied. Alternatively,
other gases can be diffused to serve as electron donors and acceptors in anaerobic and other
treatment configurations. Membrane diffusion greatly increases gas transfer efficiency, reducing
the energy needed for aeration or other gas transfer requirements.
In addition, survey respondents were asked to name other approaches that should be
considered to reduce energy use in the wastewater industry. Survey responses are noted below
for consideration in subsequent efforts.
Sewer heat recovery, non-chemical energy-heat recovery.
Pressure-retarded osmosis (osmotic power).
Anaerobic nutrient removal.
Advanced sensors for aeration control.
Non-chemical energy: micro-hydro.
Enhanced primary treatment.
“Recyllose”: fiber removal technology to reduce total suspended solids (TSS) in the aeration
basin reducing aeration need.
Bioaugmentation.
2-50
Assessment of Technology Advancements for Future Energy Reduction 3-1
CHAPTER 3.0
TECHNOLOGY COMPARISONS AND PRIORITIZATION
This chapter presents an organized comparison of the technologies presented in Chapter
2.0 based on technology maturity, expected deployment timeline, magnitude of energy impact,
and expected applicability to existing North American wastewater treatment infrastructure.
3.1 Technology Readiness Level
The estimated TRL statuses of the reviewed technologies are summarized in Table 3-1.
As noted at the bottom of Table 3-1, some survey questions were related to new approaches to
existing technologies, but these technologies were not assessed for TRL.
Table 3-1. Approximate Technology Readiness Levels.
Technology Readiness
Level TRL
Description Description
1-3
Basic or applied research
Critical function
Thermally regenerated ammonia batteries (TRABs).
Membrane production of hydrogen from wastewater.
Microbial fuel cells.
4-6 Lab testing
Prototype
Microbial electrolysis cells.
N2O production to supercharge engines.
Higher hydrocarbon production: biosolids.
Higher hydrocarbon production: biogas/bioliquids.
Mainstream shortcut nitrogen.
7-9 Pilot system
Commercial design
Deployment
Mainstream anaerobic treatment.
Pyrolysis and gasification.
Supercritical water oxidation for sludge treatment.
Aerobic granular sludge systems.
Existing
technologies
or scientific
areas: new
approaches
Modifications to deployed
technologies
Fundamental understanding of anaerobic communities.
Biogas cleanup.
Pretreatment processes for anaerobic digestion.
Enhanced methane from anaerobic digestion (other than co-digestion and
pretreatment).
Food waste co-digestion.
3-2
As noted in Chapter 1.0, previous WERF technology assessments have used a quadrant
graphic to group technologies. A similar graphical approach to prioritizing various technologies
based on input from the technical panel is shown in Figure 3-1. This figure compares the
research needs (based on TRL) to the deployment timelines projected by the survey respondents.
The deployment timeline is the sum of the estimated time required to overcome technical
challenges and the time required for commercialization. This composite timeline ranged from
approximately five years to 20 years. Technologies in the lower left quadrant appear most likely
to be adopted in the near term because these technologies are close to maturing and the
deployment timeline is estimated to be relatively short.
Figure 3-1. Technology Prioritization Based on TRL and Deployment Timeline.
Assessment of Technology Advancements for Future Energy Reduction 3-3
3.2 Impact vs. Technology Readiness Level
The TRL was also compared to a composite gauge of industry “impact.” The impact was
approximated as the product of the applicability, scale niche, and energy reduction ratings. This
metric is not a precise effort to estimate total savings (sector-wide kilowatt-hours [kWh] per
year), but reflects an approximate method for suggesting the overall potential for electrical
reductions.
Figure 3-2 depicts the relative positions of the technologies based on these criteria. This
analysis implies that the two technologies in the upper right corner will have the greatest impact
on energy use in the wastewater sector in the near term.
Figure 3-2. Technology Prioritization Based on Technology Readiness Level vs. Approximate Sector Energy “Impact”.
3-4
3.3 Economic and Energy Benefits
Survey respondents were asked to gauge the economic viability of the technologies based
on the energy savings relative to the cost of retrofits. Table 3-2 summarizes these results. While
these findings are based on divergent opinions and high-level estimates of future capital
expenditures (CAPEX) and operating expenditures (OPEX) scenarios, it provides some insight
regarding the likely relative magnitude of economic hurdles. Technologies that are used in new
projects or “end of useful life” retrofits would be expected to have a longer deployment timeline
because wastewater assets are fairly long-lived and new projects are infrequently initiated.
Table 3-2. Approximate Level of Economic Benefit.
Economic Benefit Description
Retrofits of existing equipment are likely to
be cost-effective.
Mainstream shortcut nitrogen.
Most likely to be used in new projects and
retrofits triggered by “end of useful life.”
Mainstream anaerobic treatment.
Aerobic granular sludge systems.
Pyrolysis and gasification.
Membrane production of hydrogen from wastewater.
Microbial electrolysis cells.
Supercritical water oxidation for sludge treatment.
Microbial fuel cells.
N2O production to supercharge engines.
Thermally regenerated ammonia batteries.
Somewhat challenging to make this
technology economically beneficial.
Higher hydrocarbon production: biosolids.
Higher hydrocarbon production: biogas/bioliquids.
Assessment of Technology Advancements for Future Energy Reduction 3-5
Similar to the economic benefit level, survey respondents were asked to estimate the
energy savings benefit relative to total plant energy consumption (not relative to current common
comparable processes). The results in Table 3-3 provide approximate relative rankings of these
technologies based on their perceived prospective energy savings. However, workshop
discussions clearly indicated that energy savings for individual technical approaches cannot be
accurately estimated without considering nutrient removal requirements and impacts on other
WRRF operations (e.g., upstream C diversion with mainstream deammonification).
Table 3-3. Approximate Level of Energy Benefit.
Economic Benefit Description
10% reduction or less. N2O production to supercharge engines.
10-25% reduction. Thermally regenerated ammonia batteries.
Supercritical water oxidation for sludge treatment.
Higher hydrocarbon production: biosolids.
Aerobic granular sludge systems.
Pyrolysis and gasification.
Higher hydrocarbon production: biogas/bioliquids.
Enhanced methane production from anaerobic digestion.
25-50% reduction. Mainstream shortcut nitrogen.
Microbial electrolysis cells.
Microbial fuel cells.
More than 50% reduction. Membrane production of hydrogen from wastewater.
Mainstream anaerobic treatment.
3-6
Assessment of Technology Advancements for Future Energy Reduction 4-1
CHAPTER 4.0
DEPLOYMENT OF RESEARCH FUNDING
More and more often, elected leadership and utility managers have adopted aggressive
energy- or GHG-reduction goals. While some improvements can be made by upgrades to
existing equipment, processes, and control, achieving net-zero status for many WRRFs will
require more than efficiency improvements and digester-gas-fueled CHP. For many,
transformative advances will be needed to create the necessarily dramatic reductions in power
consumption.
In juxtaposition to these goals is an apparently small investment in ongoing research to
assist in achieving these goals. WEF has recently conducted a study of research funding in the
wastewater industry. This investigation included a survey of some of the largest, most proactive
research utilities. The survey estimated how many full-time research staff (0.2-1.9%) these
utilities employ and how much of the operating budgets (0.3-2.2%) are spent on research; these
relatively low percentages are for the most proactive research utilities and suggest industry-wide
investments that are on the order of 1/10 or 1/20 of these rates. More research funding would
provide improved understanding that would identify and accelerate adoption/implementation of
new tools that might actually enable energy-reduction goals to be achieved on time, if not on an
even earlier timeline.
4.1 Discussion Framework
During this technology maturity investigation, the research team posed a question
focused on how to employ the funds. This question was not intended to rank technological
options for this investment.
“If our industry had an extra $50 million for research on energy efficiency and/or
process improvements to achieve net-zero energy, how do you think it could best be
deployed?” Specifically, the discussion addressed the following topic areas:
Size, type, number, and leveraging of grants.
What is the appropriate size for grants under this research?
Targeted team organization.
What kinds of teams would be best suited to implement this research?
Selection/award criteria.
What should the selection criteria be for award?
4-2
4.2 Visualizing Research Objectives
In order to frame the discussion of research deployment, discussion participants offered
comments related to appropriate goals for a scaled-up future research program. These goals
included:
Initiatives that target reduction in capital costs for new technology alternatives.
Award processes that appropriately define and quantify the value of projects, including
factors of potential supply and demand for technologies under consideration.
Funding targeted largely to transformative approaches.
Support for all TRL levels, from basic research all the way to commercialization, structured
to avoid the “valley of death” in which technologies are proved technically but fail in their
commercial launch.
Projects that include at minimum academic researchers and utilities; utility involvement
ground-truths the academic work and academic team members are involved early and
throughout the project duration.
Developing relationships that make it “easier to play.”
4.3 Current Research Initiative Examples
Current research programs were also cited as benchmarks for future funding structures.
Potential increased future funding would not necessarily be limited to the programs listed below,
but they do illustrate potential programs that could be expanded, leveraged via collaborations, or
modified to accelerate research progress.
4.3.1 WEF and WERF
WEF and WERF are cosponsoring the Leaders Innovation Forum for Technology (LIFT)
program. The main components of LIFT are:
Technology evaluations: Stakeholders share the cost of conducting demonstrations to
accelerate adoption of new technologies.
People and policy: Benchmarking how individual utilities accomplish R&D and
identification of resources and policies needed to implement effective R&D (WEF Lead).
Communication: Training, education, and outreach.
Informal forum for R&D: Managers and individuals responsible for technology identification
and deployment share experiences, activities, and interests .
Workshop participants believed there was potential to expand the LIFT model to drive
large research projects, including taking technology from development to implementation.
4.3.2 Department of Energy
DOE is supporting wastewater research through the following programs:
DOE’s funding structure provides initial SBIR grants in the range of $100,000 to $150,000
for small businesses to develop new technology concepts.
Assessment of Technology Advancements for Future Energy Reduction 4-3
DOE’s Advanced Research Projects Agency-Energy (ARPA-E) program provides grants on
the order of $3 million to $5 million for high-potential energy technologies that are too early
for private-sector investments.
4.3.3 National Science Foundation
NSF is supporting wastewater research through several current and upcoming programs:
The ReNUWIt Engineering Research Center (ERC) was launched in 2011. It is a 10-year
program with a total program budget of $40 million, focused on “Urban Water Reinvention”
and is a collaboration between academic organizations (New Mexico State University,
Colorado School of Mines, Stanford University, and UC Berkeley) and partner companies
and utilities. A goal of the program is to ensure support for a stream of basic research all the
way through to implementation. Future ERCs are contemplated in the food/energy/water
nexus sector.
Sustainable Research Centers are funded at $12 million over five years and support
research at 10 to 15 universities. The goal is that after five years, the research must transition
to being self-funded.
The Research Coordination Network is funded at $500,000 to $700,000 for three years.
The network’s goal is to allow principal investigators (mostly academic) to talk with one
another.
The Water Sustainability and Climate Program is funded at $25 million. This program
does not fund basic research, but rather focuses on data mining, behavioral research, and
integrating models.
An upcoming partnership between NSF and WERF will use WERF’s model of utility
collaboration to deploy NSF funding, potentially in conjunction with the LIFT program. A
similar partnership to advance energy efficiency in wastewater treatment is planned with the
Electrical Power Research Institute (EPRI).
Technical Area Workshops. NSF can provide up to $50,000 to fund workshops for a
specific topic area. For example, a workshop was proposed on identifying research needs and
gaps related to increased use of pyrolysis and gasification.
The Innovations at the Nexus of Food, Energy, and Water Systems (INFEWS) program
recently authorized $75 million for 2016 funding to support integrated experimental research,
advance knowledge/technologies, and build the future sector workforce.
4.3.4 U.S. Environment Protection Agency
The U.S. EPA is supporting research through its National Nutrients Center initiative as follows:
EPA's Office of Research and Development's Science to Achieve Results (STAR) grant
program is funding grants for several national research centers including multi-million dollar
grants for water research on National Priorities Related to a Systems View of Nutrient
Management. This includes a current multi-year STAR grant to WERF (one of four centers)
that covers projects in several areas including mainstream deammonification, low input
ammonia stripping, and urine separation.
4-4
4.3.5 International Example
Singapore was noted as an example of a leader in water research that integrated industry
and research partners and made huge advances through government investment in research and
demonstration.
4.3.6 Wastewater Utilities
To facilitate the necessary research, relationships among research institutions, industry
practitioners, and utilities need to be fostered. Examples identified included:
The City of New York fosters research through partnering with universities within the city to
answer technical challenges presented by any city agency. By matching city needs with
specific research institutions, strong working relationships have developed and long-term
research objectives are being met.
King County, Washington, developed a fellowship program with the University of
Washington to conduct needed research. The program has been in existence for 15 years.
4.4 Ideas to Maximize Effectiveness of Research Funding Deployment
Ideas for maximizing the effectiveness of research funding reflected the diverse
perspectives of the workshop participants, including academic researchers, wastewater-utility
based researchers, WERF, WEF, EPA, DOE, and NSF. The following sections summarize the
major points raised in the discussion.
4.4.1 Collaborations
Various structures and approaches were proposed to foster collaboration between
research entities and other relevant partners.
Test bed facilities were proposed to reduce the barriers for pilot testing by providing a
shared, cost-effective venue to try out new technologies and approaches. The test-bed would
be configured to minimize the risk of process disruption by discharging to a plant influent
for further treatment. The test bed facility could serve as a nucleus for a more
comprehensive research center.
Research centers were envisioned to tackle individual multi-year projects.
Research centers could also provide third-party validation services. For example, vendors
might pay a subscription for ongoing access to the research center facilities and services, but
may also pay additional fees for specific testing.
Programs that connect new technology collaborations with wastewater utilities will be most
effective if they can be timed to address a specific utility need. In other words, utilities will
be most interested in demonstrating or piloting new technologies when they are evaluating
alternatives to meet a pending process objective such as replacing aging equipment,
increasing nutrient removal, or expanding plant capacity.
Collaborations with utilities were seen as most effective when they were long term, almost
permanent. The benefits of this long-term collaboration included more robust results and
continued refinement of understanding.
Assessment of Technology Advancements for Future Energy Reduction 4-5
Participants noted that while collaborations that include in-kind support have a role in
research funding, leveraging may be less applicable to technologies that are lower on the
TRL scale.
4.4.2 Increasing Partnerships Between Research Institutions and Utilities
Participants advocated for increased partnering between research institutions with
utilities, with benefits including facilities, scale and availability, construction services, and
access to tradespeople (e.g., electrical, mechanical, etc.). However, current graduate student
program requirements can prevent research from being conducted at a utility. Many research
tools are available at universities to support utilities, but better access and funding mechanisms
need to be in place to foster their use.
4.4.3 Stimulating Research Activity
Workshop participants proposed various strategies to stimulate new research concepts
and motivate individuals who might not be well-connected to current funding sources:
Creating challenge prizes or grants to stimulate grass roots ideas and enthusiasm.
Forming an “army of new researchers.” For example, 20 postdoctoral researchers per year
could be trained as a cohort, networked to share ideas, and then deployed to various utilities
to work on site-specific research projects.
Increasing the use of “Dear colleague” letters to solicit the best ideas.
4.4.4 Grant Size
The size of grants was discussed and related to the level of technology development.
Participants noted that grants grow as the level of development increases and the stakes get
higher. For example, initial technology research could be supported by grants of $100,000 to
$200,000. As projects progress to demonstration level, grants on the order of $1 million to $5
million may be appropriate for high-potential energy technologies that are too early for private-
sector investments.
Other participants noted that the grant size factors into whether utilities are willing to
collaborate. For example, $200,000 might not be sufficient to get buy-in from the utility; the
grant size must be adequate to make it worth its while.
4.4.5 Grant Types
Various types of grants were proposed, either to expand existing approaches or to address
research needs that are not currently well funded.
Some participants proposed devoting half of the hypothetical $50 million to two centers
organized geographically around certain needs, with a five-year funding period. Beyond five
years, the centers would be funded through subscription payments from private entities.
Add-on grants were proposed to provide a pool of money for third-party oversight of
demonstration projects. Proponents stated that this auxiliary funding would make research
results more powerful and more widely accepted.
4-6
4.4.6 Team Organization
With regard to research team organization, one utility mentioned that the entity that
manages the money is an important factor of which projects they are able to participate in. For
example, they are allowed to collaborate in projects that are financially administered by a
university, but not other entities, in part because university overhead rates are relatively low.
4.5 Sample Framework to Maximize the Impact of Increased Research
Using the general concepts developed by the workshop participants and summarized
above, the authors of this report created a sample program structure based on a hypothetical $50
million increase in funding for technologies that support “Utilities of the Future” goals to recover
more resources and minimize negative environmental impacts. The dollar values indicated are
not exact targets, but rather conceptual illustrations of how additional funding could be allocated
via three primary channels.
4.5.1 WERF “Restocking” – $5 Million
In recent years, WERF has seen progressive erosion in funding levels. This funding
channel would support five to 10 more, $100,000-$200,000 WERF projects per year. In contrast
to other funding channels, this research would allow more diverse research to proceed on small-
scale, investigative projects. Currently, WERF receives between 100 and 140 proposals per year
under its unsolicited program and funds five or six projects. This very high rejection rate and the
associated level of interest suggests that additional funding could be used effectively to bolster
investment (and associated returns) using the conventional, smaller-scale, and largely “one-off”
research projects.
4.5.2 Centers of Excellence – $24 Million
The Centers of Excellence would likely be targeted at utility-led teams supported by
academics, consultants, and vendors. University-led teams could also propose and would likely
need similarly diverse teams. The proposed funding level would allow competition for six
~$4 million grants. This funding would be leveraged by a minimum 100% in-kind
cash/labor/materials contribution.
At this approximate level of funding, in combination with in-kind support, the Centers of
Excellence could either bring two or three study areas from concept to pilot-scale, or bring one
study area through pilot scale and then through full-scale demonstration. Alternatively, a portion
of the Centers of Excellence investment could be made in new or adapted test-bed facilities that
would serve multiple projects.
If a research grant-funded study area proves non-viable, the Center could petition for
adjusting or completely reassigning the grant to another study area, pending evaluation of
continued investment by a monitoring panel.
After these initial investments, these exploratory efforts should be financially self
sufficient through private capital.
4.5.3 Seed and Subsequent – $21 Million
Seed funding allows for a broader and more diverse set of proponents during the initial
phase, including smaller entities that have fewer resources to provide in-kind support. If outcome
Assessment of Technology Advancements for Future Energy Reduction 4-7
of the seed-funded research is positive, utility or private-financing backing would be required to
advance through the second stage. Only the most promising technologies would advance.
The seed funding program could start with 12 $250,000 grants with little or no leveraging
required.
Two subsequent competitions for second-stage funding would be held:
1. The first competition would be held 1.5 years after the initial solicitation and would award
two grants of approximately $3 million (with a minimum of $1 million of
cash/labor/materials in-kind leveraging).
2. The second competitions would be held three years after outset and would award four more
$3 million grants with a similar $1 million leveraging requirement. Those who were not
granted awards in the first competition would still be eligible to compete in the second.
4-8
Assessment of Technology Advancements for Future Energy Reduction R-1
REFERENCES
DOE, Biomass Multi-Year Program Plan, U.S. Department of Energy, Energy Efficiency and
Renewable Energy, 2011.
Messer, A., Logan, B, Zhang, F., http://news.psu.edu/story/336898/2014/12/03/research/low-
grade-waste-heat-regenerates-ammonia-battery, December 2014.
Ries, Matthew P., Murthy, Sudhir, Water Utility R&D: Establishing Metrics to Justify the
Investment, The Utility Management Conference, Savannah, Georgia, February 25-28, 2014.
U.S. EPA, Emerging Technologies for Wastewater Treatment and In-Plant Wet Weather
Management, EPA 832-R-12-011, March 2013.
WERF, State of Science Report: Energy and Resource Recovery from Sludge, Water
Environment Research Foundation, 2008.
WERF, Technology Roadmap for Sustainable Wastewater Treatment Plants in a Carbon-
Constrained World, Water Environment Research Foundation, 2010.
R-2
WERF Subscribers
WASTEWATER UTILITY
Alabama Montgomery Water Works
& Sanitary Sewer Board
Alaska Anchorage Water &
Wastewater Utility Arizona Avondale, City of Peoria, City of Phoenix Water Services
Department Pima County Wastewater
Reclamation Department Tempe, City of
Arkansas Little Rock Wastewater
California Central Contra Costa
Sanitary District Corona, City of Crestline Sanitation District Delta Diablo Dublin San Ramon Services
District East Bay Dischargers
Authority East Bay Municipal Utility
District Encino, City of Fairfield-Suisun Sewer
District Fresno Department of
Public Utilities Irvine Ranch Water District Las Gallinas Valley
Sanitary District Las Virgenes Municipal
Water District Livermore, City of Los Angeles, City of Montecito Sanitation
District Napa Sanitation District Novato Sanitary District Orange County Sanitation
District Sacramento Regional
County Sanitation District
San Diego, City of San Francisco Public
Utilities, City and County of
San Jose, City of Sanitation Districts of Los
Angeles County Santa Barbara, City of Santa Cruz, City of Santa Rosa, City of Silicon Valley Clean Water South Orange County
Wastewater Authority Stege Sanitary District Sunnyvale, City of Thousand Oaks, City of
Colorado Aurora, City of Boulder, City of Centennial Water &
Sanitation District Greeley, City of Littleton/Englewood
Wastewater Treatment Plant
Metro Wastewater Reclamation District
Platte Canyon Water & Sanitation District
Connecticut Greater New Haven
WPCA
District of Columbia DC Water
Florida Hillsborough County Public
Utilities Hollywood, City of JEA Miami-Dade County Orange County Utilities
Department Orlando, City of Palm Beach County Pinellas County Utilities Reedy Creek Improvement
District St. Petersburg, City of Tallahassee, City of Toho Water Authority
Georgia Atlanta Department of
Watershed Management
Augusta, City of Clayton County Water
Authority Cobb County Water
System Columbus Water Works Gwinnett County
Department of Water Resources
Macon Water Authority Savannah, City of
Hawaii Honolulu, City & County of
Idaho Boise, City of
Illinois Greater Peoria Sanitary
District Metropolitan Water
Reclamation District of Greater Chicago
Sanitary District of Decatur
Indiana Jeffersonville, City of
Iowa Ames, City of Cedar Rapids Water
Pollution Control Facilities
Des Moines, City of
Kansas Johnson County
Wastewater Lawrence, City of Olathe, City of
Kentucky Louisville and Jefferson
County Metropolitan Sewer District
Louisiana Sewerage & Water Board
of New Orleans
Maine Bangor, City of Portland Water District
Maryland Anne Arundel County Calvert County Water,
Sewerage Division Howard County Bureau of
Utilities Washington Suburban
Sanitary Commission
Massachusetts Boston Water & Sewer
Commission Upper Blackstone Water
Pollution Abatement District
Michigan Ann Arbor, City of Gogebic-Iron Wastewater
Authority Holland Board of Public
Works Saginaw, City of Wayne County Department
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WERF Subscribers Utah Salt Lake City Department
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STATE AGENCY
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CORPORATE
AECOM Alan Plummer Associates
Inc. American Cleaning Institute American Structurepoint,
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Corporation Brown and Caldwell Burns & McDonnell Carollo Engineers, P.C. CDM Smith CH2M Clear Cove Systems, Inc. D&B/Guarino Engineers
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Technologies Gannett Fleming Inc. GeoSyntec Consultants GHD Inc. Global Water Advisors Inc. Greeley & Hansen LLC Hazen & Sawyer P.C. HDR Inc. Holmes & McGrath Inc. Jacobs Engineering
Group Inc. KCI Technologies Inc. Kelly & Weaver P.C. Kennedy/Jenks Consultants KORE Infrastructure, LLC Larry Walker Associates LimnoTech McKim & Creed MWH NTL Alaska Inc. OptiRTC, Inc. PICA Corporation Pure Technologies Ltd. RainGrid, Inc. Ramboll Environ Ross Strategic Stone Environmental Inc. Stratus Consulting Inc./
Abt Associates Suez-Environnement Synagro Technologies Inc. Tata & Howard Inc. Tetra Tech Inc. The Cadmus Group Inc. The Low Impact
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America Water Services Association
of Australia List as of 10/8/15
Chair
Rajendra P. Bhattarai,
P.E., BCEE
Austin Water Utility
Vice-Chair
Art K. Umble, Ph.D., P.E.,
BCEE
MWH Global
Donald Gray (Gabb),
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East Bay Municipal
Utility District
Robert Humphries, Ph.D.
Water Corporation of
Western Australia
Terry L. Johnson, Ph.D.,
P.E., BCEE Water
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Mark W. LeChevallier,
Ph.D.
American Water
Ted McKim, P.E. BCEE
Reedy Creek
Energy Services
Carol J. Miller, Ph.D., P.E.
Wayne State University
James (Jim) J. Pletl, Ph.D.
Hampton Roads
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Michael K. Stenstrom,
Ph.D., P.E., BCEE
University of California,
Los Angeles
Elizabeth Southerland,
Ph.D.
U.S. Environmental
Protection Agency
Paul Togna, Ph.D.
Environmental Operating
Solutions, Inc.
Kenneth J. Williamson,
Ph.D., P.E.
Clean Water Services
Chair
Kevin L. Shafer
Metro Milwaukee
Sewerage District
Vice-Chair
Glen Daigger, Ph.D., P.E.,
BCEE, NAE
One Water Solutions,
LLC
Secretary
Eileen J. O’Neill, Ph.D.
Water Environment
Federation
Treasurer
Brian L. Wheeler
Toho Water Authority
Rajendra P. Bhattarai,
P.E., BCEE
Austin Water Utility
Paul L. Bishop, Ph.D., P.E.,
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University of
Rhode Island
Scott D. Dyer, Ph.D.
The Procter & Gamble
Company
Catherine R. Gerali
Metro Wastewater
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Philippe Gislette
Suez Environnement
Julia J. Hunt, P.E.
Trinity River Authority
of Texas
Douglas M. Owen, P.E.,
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ARCADIS U.S.
Jim Matheson
Oasys Water
Ed McCormick, P.E.
Water Environment
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James Anthony (Tony)
Parrott
Louisville & Jefferson
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Rick Warner, P.E.
Washoe County
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Assessment of Technology Advancements for Future Energy Reduction
Water Environment Research Foundation635 Slaters Lane, Suite G-110 n Alexandria, VA 22314-1177
Phone: 571-384-2100 n Fax: 703-299-0742 n Email: [email protected]
WERF Stock No. ENER7C13b
December 2015
Assessment of Technology Advancementsfor Future Energy Reduction
Energy
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IWA PublishingAlliance House, 12 Caxton StreetLondon SW1H 0QSUnited KingdomPhone: +44 (0)20 7654 5500Fax: +44 (0)20 7654 5555Email: [email protected]: www.iwapublishing.comIWAP ISBN: 978-1-78040-803-3
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