Biosolids - Up in Smoke?

1. Biosolids - Up in Smoke? Mark Cullington NBMA Annual Conference Lake Chelan 21 September 2010

3. (EJN, 2010)

5. Outline Thermal Conversion (Incineration) Biogasification Drivers Case Study Waste-to-energy

6. Drivers Feedstock - Annually 7,180,000 dry tons of biosolids are generated from ~16,000 WWTP’s Feedstock - Annually 250,000,000 tons of MSW Energy demand - 99,900,000,000,000,000BTU Public and political pressures (Brown, 2009; WEF, 2010; NEBRA, 2008)

7. Have developed or are considering ordinances: WA, AZ, CT, ME, NH, MA, RI, VT OH, NC, GA, FL, VA, NY, IL, WI Ban Practical Ban Restricted Use – Class A Reasonable None Biosolids Ordinances (CA EPA, 2009)

8. Drivers Feedstock - Annually 7,180,000 dry tons of biosolids are generated from ~16,000 WWTP’s Feedstock - Annually 250,000,000 tons of MSW Energy demand - 99,900,000,000,000,000BTU Public and political pressures Thermal conversion as ‘green’ energy (Brown, 2009; WEF, 2010; EPA, 2008)

10. Drivers Feedstock - Annually 7,180,000 dry tons of biosolids are generated from ~16,000 WWTP’s Feedstock - Annually 250,000,000 tons of MSW Energy demand - 99,900,000,000,000,000 BTU Public and political pressures Thermal conversion as ‘green’ energy Economies of scale (Brown, 2009; WEF, 2010; EPA, 2008)

11. (Stillwell at al., 2010)

12. Drivers Feedstock - Annually 7,180,000 dry tons of biosolids are generated from ~16,000 WWTP’s Feedstock - Annually 250,000,000 tons of MSW Energy demand - 99,900,000,000,000,000 BTU Public and political perception Thermal conversion as ‘green’ energy Economies of scale Energy recovery dollars Design-Build-Own-Operate (Brown, 2009; WEF, 2010; EPA, 2008)

13. (Adapted from United Nations, WEF, MN Metro, 1996-2010)

14. What are the best ways to capture Volatile Solids energy potential – 10,000 Btu/lb VS (23 000 kJ/kg VS)? Two “Pathways” For Energy Recovery From Biosolids Anaerobic Digestion (Adapted from Scanlon, 2009)

15. Methane Food Waste Wastewater FOG Lots of energy! Engine Electricity Digestion Class A Products Biosolids Class B Soil Amendment

16. What are the best ways to capture Volatile Solids energy potential – 10,000 Btu/lb VS (23 000 kJ/kg VS)? Two “Pathways” For Energy Recovery From Biosolids (Adapted from Scanlon, 2009)

17. Thermal Conversion (Incineration) • Combustion of organic wastewater solids to form carbon dioxide and water • Generation of heat, some gas, and ‘ash’ • Two most common types of technologies: fluid bed and multiple hearth • 254 Incinerators in the U.S: 197 Multiple Hearth, 55 Fluidized Bed, 2 Electric Arc • Every new facility built in the past 15 years has been a fluidized-bed

18. Thermal Oxidation (Incineration) (WEF, 2009)

19. Autogenously: solids ~>40% Thermal Conversion (Incineration) • Biosolids between 15-30% - for every pound of solids to be incinerated, 3-5.25 pounds of water must be evaporated (WEF, 2006; Dominak, 2001)

20. Ash generated from 400 to 800 lbs/DT of biosolids Quality of ash dependent on feedstock Thermal Conversion (Incineration) (Japan SWA, 2002)

21. Advantages Does not require pre-stabilization Destroys all volatile solids and pathogens Large volume and mass reduction lowers truck traffic as compared with other biosolids handling alternatives Low life cycle cost for most large facilities Operates continuously in all weather conditions Disadvantages High initial capital costs Applicable to large facilities Poor public perception Not the most appropriate technology for non-continuous operations Requires complex permitting process Not perceived as “green” process - N2O emissions Ash reuse programs have not been well developed Thermal Oxidation (Incineration)

22. Biogasification ‘Convert a solid or liquid substance into a gas’ Larger molecule carbonaceous solids are converted, by oxidization-reduction reactions, to smaller molecule combustible gas products In place of natural gas at sawmills, panel board plants, pulp mills, and institutional facilities using wood fuel Hallmark of process - ‘Syn Gas’ Nitrogen (55% by volume) Carbon dioxide (16%) Carbon monoxide (12% to 30 %) Hydrogen (2% to 10%)

23. Biogasification • 1. Fuel In-Feed System • 2. Gasifier ~(1200oC / 2200oF): Pyrolysis and Partial Combustion • 3. Char/Ash Removal System • 4. Syngas Source: Nexterra Systems Corp

24. Ventura County Waterworks District No. 1 Biosolids Management Study California California

25. Simi valley Moorpark Source: Ventura County General Plan Camrosa Thousand Oaks Camarillo

26. Purpose of Project • “Long-Term” Regional Solution • Reduce biosolids handling costs • Minimize quantity • Operational considerations • Explore multiple end use options (except land application) (cement aggregate, heat, electricity, methane recovery, e-fuel) • Regulatory Constraints • Evaluate Innovative and Embryonic technologies in addition to Established technologies

27. Biosolids Management Alternatives Analysis • Alternatives Selection Process • Evaluation Criteria • Technology Description • Analysis

28. Biosolids Management - Alternatives Selection Process • Deep Well Injection* (EPA, 2006)

29. Evaluation Criteria: State of development Number of Installations Discharge solids concentration Energy efficiency Space requirements Containment of foul and corrosive air Constructability (including site location) Ease of operation and maintenance Manufacturer support Life cycle costs Regulatory Approval Useful by-products Recommendations

30. Technologies - Minergy’s GlassPack • Mechanism: Vitrification (melting at 30000C, quickly followed by cooling) • Output solids used as glass aggregate • Installation: 1 plant in Wisconsin • Needs 90% solids • Business is no longer in existence Source: Minergy Corp.

31. Technologies - Plasma Assisted Sludge Oxidation (PASO) • Mechanism:Plasma oxidation in a Rotary Kiln (700oC) • Plasma: Ionized Gas; 4th state of matter • Input solids: 20% solids, FOG, food scraps, yard waste(20% organic material) • Output solids: Ash (fertilizer, cement aggregate) • No pilot / full scale installations in US Source: Fabgroups

32. Technologies - SlurryCarb® Process

33. Demonstration project (Terminal Island) under Class V UIC permit Mechanism: Sludge injected >5000 ft below earth’s surface; Biogenesis (thermal + biodegradation): Sludge  Methane, Oil, and CO2 ~400 wet tons / day Technologies - Deep Well Injection Source: City of LA, 2010; Terralog Technologies, Inc , 2010

34. Technologies - Fluidized Bed Incineration • Mechanism: Combustion • Output solids: Ash • Potential for electricity production • ~255 operating in US • Air permitting / public perception hurdles (WEF, 2009)

35. Mechanism: Pyrolysis and Partial Combustion Produces gas that is used generate electricity Output solids: Char/Ash (needs land filling / potential for cement aggregate) Needs 90% dried solids as input Technologies - Gasification Source: Nexterra Systems Corp

36. Taking it further Incineration $50-60 M Gasification $60-66 M Life-Cycle Costs: Including engineering design, O&M, Drying and Engines

37. Wrap-up Thermal conversion use in the biosolids industry is evolving First full-scale installation of biosolids gasifier in US Heavily marketed Lots and lots of volume to make these pencil-out (life-cycle costs)

38. Mark Cullington markcullington@kennedyjenks.com (503) 866-4188