Reuse, Recover, Recycle Stefan Salzmann 4th November 2018 · Alkali-wäscher Speisewasser-behälter Schlammanlieferung extern Schlammanlieferung intern Störstoff-abscheider Emissions-messungen

Centralized Sludge Incineration Reuse, Recover, Recycle

Stefan Salzmann 4th November 2018

© Outotec – All rights reserved

Outotec

2

F&E, Verkaufs- und

Servicezentren in

36 Ländern

Lieferungen in mehr als

80 Länder Mitarbeiter

von über

60 Nationalitäten

Umsatz MEUR 1.139 in 2017

4.146 Mitarbeiter


Sludge disposal canton Zürich - Strategy

•In year 2005 canton Zürich launched the strategy for coordinated sewage sludge disposal

•The reason for that: • Disposal security for the whole canton • Possibility for phosphorous recovery • Energy usage • Costs for disposal

• In year 2010 the decision was made to build a centralized sewage sludge incineration plant in Zürich Werdhölzli

•Since 2015 the delivery of dewatered sludge from the whole canton to the incineration plant is taking place the plant is in operation

4/12/2018 Centralized sludge incineration, Stefan Salzmann 3


Facts and numbers in canton Zürich

•100 000 t/a sludge formation with 20-40% DM in more than 70 waste water treatment plants

•70 000 t/a sludge needs to be transported

4 Centralized sludge incineration, Stefan Salzmann 4/12/2018


Sewage sludge utilization plant in Zürich



Process Flow Diagram

6

G

Ca(OH)2

Trockner 1

Trinkwasser

KWH

Deminanlage

Sand

Trockner 2

SPW Behälter

GAA

Brauchwasser

Aktivkohle

Wirbelschicht-ofen

Abhitzekessel

Elektrofilter

Sprüh-trockner

Gewebefilter

Turbine

Schlammbunker

Saugzug Kamin

Verbrennungsluftgebläse

Brüdenkondensation

ReststoffAsche è P-Recycling

Reaktor SaurerWäscher

Alkali-wäscher

Speisewasser-behälter

Schlammanlieferung extern

Schlammanlieferung intern

Störstoff-abscheider

Emissions-messungen

Kondensat-behälter

HD-Dampf (Hochdruck)

ND-Dampf (Niederdruck)

Erdgas

Deminwassertank

Kühlwasserkreislauf

Wärme zur KWH

Brüdenkondensat zum Klärwerk

Rücklauf von KWH

ND-Dampf

KSV Zürich Verfahrenstechnisches ProzessschemaKlärschlammverwertung

Baujahr 2015GAA

Trockner

Druckluft

Kompressoren

NotstromdieselDiesel

Wäscher

H2O

Verdichter

850°C – 950°C

24 000 m³/h i.N.

875 kWel

100 000 t/a =30 000 tTS/a

150 - 400°C

160 -180°C

120 - 140°C

75°C

4 500 kWth

16 000 m³/h i.N.

Normalbetrieb: 0 Nm³/h

Biofilter

Dampftrommel

14 000 t/a 600 t/a

NH4OH

SNCR

Wärme zur GAA

Rücklauf von GAA

1 000 kWthND-Dampf

NaOH

ND-Dampf

130°C

95°C

Emissionen nach LRVStaub < 10 mg/Nm³Pb+Zn < 1 mg/Nm³Hg < 0,1 mg/Nm³Cd < 0,1 mg/Nm³SO2 < 50 mg/Nm³HCl < 20 mg/Nm³HF < 2 mg/Nm³NOX < 80 mg/Nm³NH3 < 5 mg/Nm³CO < 50 mg/Nm³Dioxine < 0,1 ng/Nm³

27 000 m³/h i.N.

ND-Dampf

Speise-wasser

Speise-wasser

450°C9,7 t/h

60 bar 7 bar170°C

ND-Dampf

Centralized sludge incineration, Stefan Salzmann 4/12/2018


North elevation

7

Solid Building • Sludge Bunker • Rooms for Electrical Eqt. • Central HVAC • Control Room • Biofilter (on roof)

Incineration Hall (Structural Steel)

• Main Process Eqt.

Centralized sludge incineration, Stefan Salzmann

22 m

4/12/2018


Main guaranties and achieved values for the nominal capacity

8

Description Unit Guarantee Achieved Comment

Power production kWh/h 875 910 Higher heating value

Power consumption kWh/h 850 < 830 Process and potable water m³/h 5 5

Natural gas Nm³/h 420 MWh per year incl. star-up

0 in operation

Caustic soda NaOH kg/h 62 155 Guarantee based on 0,5% S in sludge, actual 1,0 – 1,2%

Lime hydrate Ca(OH)2 kg/h 19 20

Ammonia water NH4OH kg/h 45,3 < 5 In normal operation rarely needed

Activated carbon kg/h 1,25 < 1 Continuously Hg measurement

Sand kg/h 2,5 0 Depends on sand amount in sludge

Heat output kWh/h 4’450 4’550



Operational data KSV for 2016

9

Parameter Value Unit

Hours of operation 7‘388 h

Revision acc. to plan 987 h

Unplanned disturbance 244 h

Unplanned disruption (sludge not available) 165 h

Burned sludge 84‘131 t

Steam production 60‘435 MWh

Power production 5‘282 MWh

Power consumption 5‘694 MWh

Heat production (usefull heat) 27‘715 MWh

Sludge ash 13‘404 t

Residue from flue gas cleaning 709 t



Emissionslimits for Switzerland and Europe

Parameter Switzerland LRV (Luftreinhalte-verordnung)*

Europe Guideline 2010/75

Unit

CO 50 50 mg/m³ i. N.

SO2 50 50 mg/m³ i. N.

HCl 20 10 mg/m³ i. N.

HF 2 1 mg/m³ i. N.

Dust 10 10 mg/m³ i. N.

NOx als NO2 80 200 mg/m³ i. N.

NH3 5 non mg/m³ i. N.

Cd 0,1 mg/m³ i. N.

Cd + Tl 0,05 mg/m³ i. N.

Hg 0,1 0,05 mg/m³ i. N.

Pb + Zn 1 mg/m³ i. N. Sb, As, Pb, Cr, Co,

Cu, Mn, Ni, V 0,5 mg/m³ i. N.

Dioxine und Furane 0,1 0,1 ng TEQ/m³ i. N *daily average



Achieved yearly emissions 2017, Average

Parameter Switzerland LRV (Luftreinhalte-verordnung)*

Achieved (average of the CEMS

in 2017) Unit

CO 50 2,1 mg/m³ i. N.

SO2 50 7,2 mg/m³ i. N.

HCl 20 0,1 mg/m³ i. N.

Staub 10 2,3 mg/m³ i. N.

NOx als NO2 80 41,6 mg/m³ i. N.

NH3 5 2,2 mg/m³ i. N.

Hg 0,1 0,01 mg/m³ i. N. *daily average



Zürich – successful in operation since 2015



Down stream process for ash from SIP •Ash from SIP contains 10–22 % of P2O5

•> 99.8 % of the ash is removed as “clean ash” in the ESP of the SIP

•A long list of different process developments are known wet or thermal

•Outotec’s Ashdec process converts ashes into a plant available P-fertilizer

•Trials with ashes from SIP have shown positive results on P-solubility in neutral Ammonium Citrate.

13 Centralized sludge incineration, Stefan Salzmann

Outotec, Frankfurt

4/12/2018


Summary

14 Centralized sludge incineration, Stefan Salzmann

Sludge Incineration Zürich •Successful in operation since 2015

AshDec •Thermochemical process with alkaline compound

•Low residue amount •Possible integration to incineration plant

•P recovery > 95 % •PNAC > 80 %

NAC = Neutral ammonium citrate

4/12/2018

Documents

Reuse, Recover, Recycle Stefan Salzmann 4th November 2018 · Alkali-wäscher Speisewasser-behälter Schlammanlieferung extern Schlammanlieferung intern Störstoff-abscheider Emissions-messungen