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END-O-SLUDG an innovative holistic system approach to sludge management

END-O-SLUDG an innovative holistic system approach to sludge management. Author: Dr. Son Le, MBE (presenting author Herman Sioen, WATERLEAU) Meeting: “ La gestion innovante des boues d’épuration à l’échelle européenne ” (CEME Charleroi, 22 October 2013) . AIM & OBJECTIVE.

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END-O-SLUDG an innovative holistic system approach to sludge management

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  1. END-O-SLUDGan innovative holistic system approach to sludge management Author: Dr. Son Le, MBE (presenting author Herman Sioen, WATERLEAU) Meeting: “La gestion innovante des boues d’épuration à l’échelle européenne”(CEME Charleroi, 22 October 2013)

  2. AIM & OBJECTIVE Aim: to have marketable sludge derivatives from sustainable processing of wastewater in a highly integrated treatment plant. Objective: To research, develop and demonstrate a toolkit of novel processes together with development the market and integration methodologies that can be applied for sustainable sludge management. 2

  3. Scope of Project EU FP7 END-O-SLUDG Project, Author: 4

  4. Activated sludge or trickling filter 2° sediment Sludge 1.1 Sludge arising from conventional works Advanced treatment Tertiary treatment 1° sediment Treated effluent Sludge Sludge Sludge Anaerobic digester Biogas Biosolids 5

  5. P sludge VFA DAF BIOSORBENT 1.1 Concept of Sludge Reduction Advanced treatment Tertiary treatment 1° sediment Treated effluent Sludge Sludge Sludge Anaerobic digester Biogas Biosolids 6

  6. 1.3 DAF performance Trials in The Netherlands TSS removal from >99% COD removal from up to 80% ASP load reduction 59% 7

  7. 1.4 Sorbent performance 8

  8. 2. Sludge Treatment • Pre-treatments • Inverted phase fermentation • Digestion intensification • Competitive exclusion 9

  9. 2.1 Ultrasonic sonication Ultrasonic has most pronounced effect on SAS compared to other sludge types Ultrasound pre-treatment of secondary sludge from Baíña WTP (numbers = specific energy applied, kJ/kgTS) 10

  10. 2.2 Inverted Phase Fermentation 11

  11. 2.3 Digestion intensification 12

  12. Probiotic culture E. coli culture Competition culture: BROM1 and E. coli 2.4 Competitive exclusion 13

  13. High quality product for end-o-waste (OMF Manufacture) Resource recovery (N & P) 3. Downstream Processing Liquor treatment 14

  14. 3. 1 The OMF challenge • Product requirement: • Granular, free flowing, dust free • 3-5mm size, >1.3 g/cc • Guaranteed nutrient content • Issues: • Energy intensive process • High wearing / high maintenance • Explosion risk 15

  15. 3. 2 Two-stage OMF manufacturing process 16

  16. boiler air, fuel incondensables condenser warm water vapours cooling water sieve oil pump granule recirculation coater coated pellets vertical transport condensate to treatment LilliPutt ® pilot granulator Dry granules (>90%DS) to storage Green granules (<65%DS) to dehydration unit Nutrient dosing Digested sludge cake Nutrients (urea/TSP) sludge pump granules 3. 3 First stage – Waterleau PUTTART® technology 17

  17. 3. 4 second stage – Valsave THERMALOOP™ technology 18

  18. 3.5 OMF Pilot plant (Ellesmere Port) Granulator unit Dehydration unit (artist impression) 19

  19. PuttArt® vertical disc dryer-granulator Shell (insulated) Trays Raking arms with ploughs Cold structure Central rotating shaft Drive Reference plant: Poznan, Poland 3 lines of each 3.1 TPH H2O evap.

  20. LilliPutt® Mounting on site

  21. LilliPutt® In operation First granules LilliPutt® Test plant in operation

  22. LilliPutt® Key data • Technology: LilliPutt® • Plant Capacity • Dry solids 2.4 TPD • Wet Cake 12 TPD • Evaporation 10 TPD • N° of lines 1 • Wet Sludge Data • Digested secondary municipal sludge • 21% dry solids • Dry Sludge Data • >90% dry solids • Start of operation: November 2012 • Current status: test completed, plant will be decommissioned this month • Site location: Ellesmere Port, (Manchester), UK

  23. 4. Market Development • Aim: To develop a distinct knowledge base by which farmers and agriculturalists integrate OMF-based products. • Two products to be developed: • Grassland application (NPK: 10-4-0) • Arable crop application (NPK: 3-8-0) • Note : Digested sludge = NPK 4-5-0 • Market demand key factor in gaining End of Waste status

  24. 4.1 Plot trials at Broxton (Cheshire)

  25. 4.2 Plot trials at Broxton (Cheshire) Deeks LK, Chaney K, Murray C, Sakrabani R, Gedara S, Le MS, Tyrrel S, Pawlett M, Read R, Smith GH (2013). Field evaluation of a sewage sludge derived novel organo-mineral fertilizer on combinable crops. Agronomy for Sustainable Development DOI 10.1007/s13593-013-0135-z

  26. 4.3 End of Waste: Practical Steps • Product status is key aim of the OMF development • Legal status is complex • Demonstrate equivalence with existing fertilisers • Development of specifications for OMF • Continuing plot/field trials • Development of grower protocols • Engage with Regulators

  27. 4.4 End of Waste: Market Development • Sustainable, renewable sources of phosphate are required. • OMF has the potential to fulfil market requirements • Unlike UK the application of biosolids to land is not universally accepted by all stakeholders. E.g. Netherlands recycling is prohibited. • END-O-SLUDG working to address these issues

  28. CONCLUSION • END-O-SLUDG aims to create a portfolio of useful new products from sludge that meet End of Waste as part of a new concept for sewage sludge management in Europe. • This involves development of new technologies for: • Sludge volume reduction • More efficient sludge treatment • Economical downstream processing • Renewable source of P that could sustainably support crop production • Results so far have been very promising 29

  29. www.end-o-sludg.eu Dr. Son Le, MBEMS.Lee@uuplc.co.uk Herman Sioen herman.sioen@waterleau.com Acknowledgement: The research leading to these results has received funding from the European Union Seventh Framework Programme (FP7-ENV.2010.3.1.1-2 ENV) under grant agreement N° 265269.

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