Phosphorus recovery from sewage sludge

– state of the art–

Dr. Christian Kabbe

Wasser Berlin International

24th April 2013

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www.p-rex.eu

Phosphorus – bottleneck of life

www.p-rex.eu

Limited availability Strategic resource

„We may be able to substitute nuclear power for coal, and plastics for wood,

and yeast for meat, and friendliness for isolation

– but for phosphorus there is neither substitute nor replacement“.

- Isaac Asimov (1920 bis 1992) – First published 1959 (Life‘s bottleneck)

- Wastewater/sewage sludge - Biowaste - Manure - Meat and bone meal

The traditional, closed anthropogenic P cycle

www.p-rex.eu

Once upon a time, there was an unbroken circle …

http://www.nhm.ac.uk/research-curation/research/projects/phosphate-recovery/ceep11.htm

Soil <-> life balance …

The modern anthropogenic P „cycle“

www.p-rex.eu

Disruption of P cycle: Urbanization Industrialisation Globalisation

Problems: - Dislocation of food production and consumption - Pollutants/contamination - Inefficient use (only 20-25% from mine to fork)

Challenges for the future: - Increasing P demand - Decreasing quality of fossil P rock - Limited availability - Dependencies (geopolitics …)

Need of mineral fertilizer to compensate losses!

EU needs to import 975,000 t/a of mineral P!!!

http://www.nhm.ac.uk/research- curation/research/projects/ phosphate-recovery/ceep11.htm

Closing the loop, but where and how?

www.p-rex.eu

amended from: http://www.nhm.ac.uk/research-curation/research/projects/phosphate-recovery/ceep11.htm

210 Mt P rock (global mining 2012, USGS 2013)

90%

10%

P efficiency from mine to fork: below 25%

Sewage sludge routes in Europe 2010

www.p-rex.eu

(DESTATIS 2012)

Obviously: insufficient reuse of P

0

250000

500000

750000

1000000

1250000

1500000

1750000

2000000

AT BE BG CY CZ DE DK EE ES FI FR GR HU IE IT LT LU LV MT NL PL PT RO SE SI SK UK CH

other

landfill

application to land

incineration

Dry

ma

tte

r in

me

tric

to

ns

European total quantity: ~ 11 million tons sludge (dry matter)

Germany‘s national P Reserves

www.p-rex.eu

Waste stream Quantity of waste

stream

P-Reserve

(theoretical)

Compared to

Pmineral imported

~ 120.000 t/a

wastewater

(municipal) ~ 9,4 billion m³/a ~ 75.000 t P/a ~ 63 %

sewage sludge

(dry matter)

As a fraction of

wastewater

~ 2 million t/a ~ 67.500 t P/a ~ 57 %

meat & bone meal ~ 180.000 t/a ~ 10.800 t P/a ~ 9 %

animal excreta

manure: ~ 190 Mio m3/a

~ 240.000 t P/a Completely but not

efficiently used! solids: ?

6% of German cropland (12 million acres in total) short of P, whereas NS and NRW have surplus sufficient for 1 million acres from manure (Römer et. al. 2013)

(Different sources DESTATIS)

WATERLOOP – Trinity of P Recycling

www.p-rex.eu

Food

Humans

Wastewater

WWTP

Agriculture

Sewage sludge D

ire

ct a

pp

licat

ion

o

n a

rab

le la

nd

P r

eco

very

fro

m

aqu

eo

us

ph

ase

(M

AP

)

P r

eco

very

fro

m

inci

ne

rati

on

ash

EU: 11 million tons of sludge dry matter/a ~ 350,000 t P/a

P

Global P recycling from wastewater: End of 20th century only 30%! (Liu et al. 2008)

Hot spots for P recovery in WWTP

www.p-rex.eu

(amended from Montag 2010)

P recovery processes in Europe

www.p-rex.eu

PEARL MAP

Ash

Sludge/ Sludge Liquor

LEACHPHOS P-mineral

Thermal

Leaching

P-bac (INOCRE) MAP

P-RoC CaP/CSH

PASCH CaP

MEPHREC P-slag

LYSOGEST MAP

Gifhorn MAP, CaP

AirPrex MAP FULL

NuReSys MAP

PHOSPAQ MAP

ICL Fertilizer fertilizer

AshDec (SUSAN) P-mineral

RECOPHOS D P-mineral

SESAL-PHOS CaP

KREPRO FeP

Budenheim CaP

RECOPHOS AT H3PO4

Crystalactor MAP, CaP

FIX-PHOS CaP/CSH

REPHOS MAP

ECOPHOS P-mineral

Planned demo

Planned full-scale

full-scale

Stuttgart MAP

PHOSTRIP MAP, CaP

THERMPHOS P4 ?

P recovery units - sludge Process Operator/location Scale Output Contact

P recovery from sludge

AirPrex Waßmannsdorf (DE)

BWB full

MAP

Berliner Pflanze

Berliner Wasserbetriebe

Dr. B. Heinzmann

AirPrex MG-Neuwerk (DE)

Niersverband full MAP

P.C.S.

W. Ewert

AirPrex BS-Steinhof (DE)

SE|BS / AVB full

MAP/

Sludge

P.C.S.

W. Ewert

AirPrex Wieden-Echten (NL) full MAP P.C.S.

W. Ewert

AirPrex Amsterdam (NL)

planned full MAP

P.C.S.

W. Ewert

LYSOGEST Lingen (DE)

SE Lingen full MAP

P.C.S.

W. Ewert

NuReSys Leuven (BE)

Aquafin full

MAP

BIOSTRU

NuReSys

C. Dewaele

PHOSPAQ Olburgen (NL)

Waterstromen full MAP

Waterstromen

R. Haarhuis

PHOSPAQ Lomm (NL)

Waterstromen full MAP

PAQUES

M. Weghuis

CRYSTALACTOR Geestmerambacht (NL) full CaP DHV

A. Giesen

Gifhorn

process

Gifhorn (DE)

ASG full MAP

PFI

Prof. J. Müller-Schaper

Fix-Phos Hildesheim (DE)

SEHi full

CaP/

Sludge

TU DA

Dr. C. Schaum

Stuttgart

process Offenburg (DE) pilot MAP

IAT

Mr. Meier

Budenheim process Mainz (DE) pilot CaP Budenheim

Dr. R. Schnee

P recovery units – process water

www.p-rex.eu

Process Location/Operator Scale Output Contact

P recovery from sludge liquor / process water

REPHOS Altentreptow (DE)

Remondis Aqua full MAP

Remondis

Dr. M. Lebek

PEARL

(PEARL 500)

Slough (UK)

Thames Water full

MAP

Crystal

Green™

OSTARA

Jim Hotchkies

NuReSys

(prototype) Dairy processing (BE) full

MAP

BIOSTRU

NuReSys

C. Dewaele

NuReSys Potato processing (BE)

Harelbeke full

MAP

BIOSTRU

NuReSys

C. Dewaele

NuReSys Potato processing (BE)

Nieuwkerke full

MAP

BIOSTRU

NuReSys

C. Dewaele

NuReSys Potato processing (BE)

Waasten full

MAP

BIOSTRU

NuReSys

C. Dewaele

NuReSys Pharmaceutical ind. (BE)

Geel full

MAP

BIOSTRU

NuReSys

C. Dewaele

P-RoC Neuburg (DE) pilot CaP KIT CMM

Dr. R. Schuhmann

PHOSTRIP Brussels-North (BE)

Aquiris (Veolia Eau) pilot MAP or CaP

Veolia Eau

H. Paillard

P recovery units – during or after incineration

www.p-rex.eu

Process Location/Operator Scale Output Contact

P recovery during or after incineration

MEPHREC

Nürnberg (DE)

SUN

(planned)

full P fertilizer Ingitec

J. Mallon

SUSAN

(Ash Dec)

Koenigs Wusterhausen

(DE)

RETERRA

(planned)

full P fertilizer Outotec

Ludwig Hermann

Commercial

fertilizer production

Amsterdam (NL)

Ludwigshafen (DE) full P fertilizer

ICL Fertilizers

Kees Langeveld

Thermphos* Vlissingen (NL) full White P4 Willem Schipper

LeachPhos MSWI plant of Bern (CH) pilot MAP or CaP BSH

Stefan Schlumberger

EcoPhos/SNB/HVC

EcoPhos

(BE)

(planned)

full DCP SNB

M. Lefferts

?

P recovery – feasibility example

www.p-rex.eu

dry matter

content after

deatering

cost Fe-saltdisposal cost

sludge

opex Air-

PrexRockAway total cost

TR (%) €/a €/a €/a €/a €/a

Fe-salt 20 g/m³

Influent ß= 1,329 503.953 2.585.480 0 0 3.089.433

Bio-P with

RockAway20 0 3.176.366 0 150.000 3.326.366

Bio-P with

AirPrex25 0 2.537.942 314.153 0 2.852.095

Benefits due to AirPrex unit: - Reduced maintenance (no more clogged pipes), centrifuges run smoother - Improved dewaterability of sludge (+ ~5% dry matter ) -> reduction of disposal costs - Reduced chemicals consumption - Annual cost reduction: 474,000 €

The practical example of WWTP Neuwerk (Niersverband):

(Niersverband, Bäckler 2012)

How to increase P-recovery rate from wastewater?

www.p-rex.eu

Demonstration and systematic validation of technical processes at full-scale facilities

Systematic assessment and validation of the quality of obtained recycling products with regards to plant availability of phosphorus and eco-toxicity

Analysis of market barriers and market potential for novel recycling

technology and recycling products Development of strategies and recommendations for efficient and

wide-spread phosphorus recovery and market penetration from the wastewater stream with regards to specific regional conditions -> policy brief, guidance document

P-REX: Project Goals

EU-wide implementation of P recovery/recycling from wastewater stream with respect to regional conditions and demands

Project structure

www.p-rex.eu

WA1 – DEMO and technical assessment of P recovery from ash

WA2 – DEMO and technical assessment of P recovery from sludge (aqueous phase)

WA3 – DEMO and assessment of direct sludge valorization on arable land • Incl. measures for reduction of sludge toxicity (green polymers etc.) • Demonstration bio-test based monitoring routines

WA4 - Environmental impact and costs of compared technologies in relation to traditional valorization of sewage sludge and commercial mineral fertilizers

• Product quality (plant availability, eco-toxicity) • LCA (environmental impacts based on widely agreed LCA methodology) • LCC (costs for P recovery options also based on agreed mthodology)

WA5 – Europe-wide implementation • Market barriers, requirements and options, • Legal framework in Europe and enduser requirements • Stakeholder workshops (market survey and regional conditions) • Integral guidance document and policy brief for implementation • E-market for P-recycling products

WA6 – Management and Dissemination

Enabling technology: Feasibility? Infrastructure? Process stability?

Products: What are the real market requirements besides legal requirements

How to establish a market for recycled P?

www.p-rex.eu

P recovered P recovered P recovered

LEGAL framework Nutrient concentration Pollutants Plant availability Eco-toxicity Hygiene

Market framework Price Purity (MAP?) Odour Quantity Shape Handling Operational benefits? Consumer concerns?

(BWB)

Resume/Outlook

www.p-rex.eu

Struvite recovery is state of the art for P recovery/recycling (limited to Bio-P plants and recovery max 50%)

-> already a growing market in terms of process technology, esp. when additional benefits for operator -> still need to develop market for products (MAP, HAP etc.) several thousand tons per year within the next 2 years -> REACH!!! Waste to product! -> whereas legal requirements are quite clear, the real end-user needs are still hidden (farmers needs, fertilizer industry) -> enhancement by combination with thermal-hydrolysis and appl. on excess activated sludge (LYSOPHOS)

Recovery P from ash higher recovery potential (>80%)

-> fertilizer manufacturer already recycle ash (ICL) -> leaching and thermochemical facilities about to be installe within next years

Traditional P recycling (bio-solids) in agriculture -> concerns -> source control, monitoring routines, transparency -> creation of trust

Infrastructure / synergies or technology applicable for manure other waste streams?

Outlook - Actions

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Open other perspectives -> bring them together!

Trans-sectoral multi stakeholder cooperation, joint forces

Definition of quality criteria (legal and market) Set up logistics for distribution Test products under real conditions with farmers Process development/optimization

Science Problem analysis

Practice

Problem solution,

innovation

Policy

Impulses, framing

conditions

Outlook – Create opportunities

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Adaption of WWTP towards P optimized sludge treatment

Certification of i.e. MAP for fertilizer in all over Europe (also org. agr.)

Learning from successful model cases (AirPrex, Ostara etc.)

Optimization of running full-scale facilities

Applied R&D!!! -> innovation is application

Creation of demand for rec. products (awareness, pre-normative

matrix) for available material

Outlook - Policy

www.p-rex.eu

EU / National P flows and waste concepts -> knowing where the hot-spots are, what synergies can be applied, (cross-border MFA)

Reasonable adaption of legislation towards higher P efficiency (waste, wastewater …)

Financial support of demo plants (HORIZON 2020, EIP, UIP …)

Innovation risk fund (to promote/allow innovation)

EU-wide market for P-rec products needs harmonized requirements

Support European and national P (Nutrient) platforms to boost smart cooperation

Acknowledgement

www.p-rex.eu

P-REX is a research and demonstration

project supported by the European Commission

under the Seventh Framework Programme

(Priority: “From Prototype To Market”)

Contract No. 308645 – P-REX

Duration: 01/09/12 - 31/08/15

KWB is co-financed by Veolia and Berliner Wasserbetriebe (BWB)

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Thank you for your kind attention!

Christian.Kabbe@kompetenz-wasser.de

www.phosphorusplatform.eu

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