dr. Christian Kabbe

FROM PROTOTYPE TO MARKET
PHOSPHORUS RECYCLING
Quantity, Quality and Market aspects of
potential P recycling routes in Europe
Christian Kabbe
Berlin Centre of Competence for Water
Wageningen, 6th February 2013
www.p-rex.eu
Phosphorus – bottleneck of life
„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)
Limited availability
Strategic resource
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The traditional, closed anthropogenic P cycle
Once upon a time, there was an unbroken circle …
Soil <-> life balance …
- Wastewater/sewage sludge
- Biowaste
- Manure
- Meat and bone meal
http://www.nhm.ac.uk/research-curation/research/projects/phosphaterecovery/ceep11.htm
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The modern anthropogenic P „cycle“
Problems:
- Discoupling of food production and consumption
- Pollutants/contamination
- Inefficient use
http://www.nhm.ac.uk/researchcuration/research/projects/
phosphate-recovery/ceep11.htm
Need of mineral fertilizer
to compensate losses!
EU needs to import 975,000 t of mineral P!!!
Disruption of P cycle:
Urbanization
Industrialisation
Globalisation
Challenges for the future:
- Increasing P demand
- Decreasing quality of fossil P rock
- Limited availability
- Separation of nutrients from
pollutants for recycling
www.p-rex.eu
Building Bridges!
FROM PROTOTYPE TO MARKET
PHOSPHORUS RECYCLING
EU FP7 Project
Sustainable sewage sludge management
fostering phosphorus recovery and energy
efficiency
www.p-rex.eu
Closing the loop, but where and how?
10%
90%
210 Mt P rock
(global mining
2012, USGS
2013)
amended from: http://www.nhm.ac.uk/research-curation/research/projects/phosphate-recovery/ceep11.htm
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Germany‘s National P Reserves
P-Reserve
(theoretical)
Compared to
Pmineral imported
~ 120.000 t/a
~ 9,4 billion m³/a
~ 75.000 t P/a
~ 63 %
sewage sludge
(dry matter)
~ 2 million t/a
~ 67.500 t P/a
~ 57 %
meat & bone meal
~ 180.000 t/a
~ 10.800 t P/a
~9%
~ 240.000 t P/a
Completely but not
efficiently used!
Waste stream
wastewater
(municipal)
Quantity of waste
stream
manure: ~ 190 Mio m3/a
animal excreta
solids: ?
6% of German cropland (12 million acres) short of P, whereas NS
and NRW have surplus sufficient for 1 million acres from manure
(Different sources DESTATIS)
(Römer et. al. 2013)
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Sewage sludge routes in Germany
sewage sludge in metric tons dry matter
2200000,0
2000000,0
3%
1800000,0
13%
1600000,0
29%
1400000,0
1200000,0
1000000,0
800000,0
600000,0
55%
400000,0
200000,0
,0
1998
2001
thermal
2004
agriculture
2007
landscaping
2008
landfill
2009
other
2010
2011
interim storage
(DESTATIS 2012)
Obviously: insufficient reuse of P
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Sewage sludge routes in Europe 2010
2000000
European total quantity: ~ 11 million tons sludge (dry matter)
1750000
other
Dry matter in metric tons
1500000
landfill
application to land
1250000
incineration
1000000
750000
500000
250000
0
2012)
AT BE BG CY CZ DE DK EE ES FI FR GR HU IE IT LT LU LV MT NL PL PT RO SE (DESTATIS
SI SK UK CH
Obviously: insufficient reuse of P
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WATERLOOP – Trinity of P Recycling
Wastewater
P
WWTP
Global P recycling from wastewater:
End of 20th century only 30%!
P recovery from
incineration ash
Humans
P recovery from
aqueous phase (MAP)
Agriculture
Direct application
on arable land
Food
Sewage sludge
EU: 11 million tons of sludge dry matter/a
~ 350,000 t P/a
(Liu et al. 2008)
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Hot spots for P recovery in WWTP
(amended from Montag 2010)
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Some P recovery processes in Europe
P-RoC
CaP/CSH
DEMO
PHOSTRIP
Sludge Liquor
MAP, CaP
With Leaching
Wet Oxidation
Leaching
FULL
AirPrex
MAP
FULL
Gifhorn
MAP, CaP
MAP
MAP, CaP
REPHOS
MAP
Full
NuReSys
MAP
Sludge
Electrochemical
LYSOGEST
DEMO
PEARL
Low Chemicals
Demand
PRISA
FULL
MAP, CaP
Budenheim
FIX-PHOS
CaP
CaP/CSH
DEMO
MAP
FULL
DEMO
KREPRO
DEMO
Aqua Reci
PHOXNAN
H3PO4
H3PO4
LEACHPHOS
P-bac (INOCRE)
P-mineral
MAP
DEMO
Full
Crystalactor
MAP
Stuttgart
DEMO
MAP
FeP
SEPHOS
SESAL-PHOS
PASCH
AlP
CaP
CaP
MEPHREC
AshDec (SUSAN)
FULL
Ash
Thermal
P-slag
DEMO
P-mineral
DEMO
RECOPHOS D
RECOPHOS AT
THERMPHOS
P-mineral
H3PO4
P4
DEMO
DEMO
?
FULL
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P recovery units - sludge
Process
Operator/location
Scale
Output
Contact
MAP
BWB
Dr. B. Heinzmann
P recovery from sludge
AirPrex
Waßmannsdorf (DE)
BWB
full
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
CRYSTALACTOR
Geestmerambacht (NL)
full
Ca-P
DHV
A. Giesen
Gifhorn process
Gifhorn (DE)
ASG
full
MAP
PFI
Prof. J. MüllerSchaper
Fix-Phos
Hildesheim (DE)
SEHi
full
Ca-P/
Sludge
TU DA
Dr. C. Schaum
Stuttgart process
Offenburg (DE)
pilot
MAP
IAT
Mr. Meier
Budenheim process
Mainz (DE)
planned
pilot
Ca-P
Budenheim
Dr. R. Schnee
Berliner Pflanze
www.p-rex.eu
P recovery units – process water
Process
Operator/location
Scale
Output
Contact
P recovery from sludge liquor / process water
REPHOS
Altentreptow (DE)
Remondis Aqua
full
MAP
Remondis
Dr. M.
Lebek
LYSOGEST
Lingen (DE)
SE Lingen
full
MAP
P.C.S.
W. Ewert
PEARL
(PEARL 500)
Slough (UK)
Thames Water
full
NuReSys
(prototype)
Dairy processing (BE)
full
NuReSys
Potato processing (BE)
full
P-RoC
Neuburg (DE)
pilot
Ca-P at CSH
KIT CMM
Dr. R. Schuhmann
PHOSTRIP
Brussels-North (BE)
Aquiris (Veolia Eau)
pilot
MAP or Ca-P
Veolia Eau
MAP
Crystal Green™
MAP
BIOSTRU
MAP
BIOSTRU
OSTARA
Jim Hotchkies
NuReSys
Dr. Wim Noerman
NuReSys
Dr. Wim Noerman
www.p-rex.eu
P recovery units – during or after incineration
Process
Operator/location
Scale
Output
Contact
MEPHREC
Nürnberg (DE)
SUN
full
P-fertilizer
Ingitec
J. Mallon
SUSAN
Koenigs Wusterhausen
(DE)
RETERRA
full
P fertilizer
Outotec
L. Hermann
Thermphos
Vlissingen (NL)
full
White P4
Thermphos
Willem Schipper
LeachPhos
MSWI plant of Bern
(CH)
pilot
MAP or
CaP
BSH
S. Schlumberger
RECOPHOS
?(DE)
full
P fertilizer
RecoPhos
Mr. Bohndick
?
Tangermünde (DE)
full
P fertilizer
Loser Chemie
Mr. Loser
What about Aquafin and EcoPhos?
P recovery during or after incineration
Undiluted incineration -> ash
Highest recovery potential (> 90% P compared to influent)
www.p-rex.eu
P recovery - feasibility
The practical example of WWTP Neuwerk (Niersverband):
dry matter
disposal cost opex Aircontent after cost Fe-salt
RockAway total cost
sludge
Prex
deatering
Fe-salt 20 g/m³
Influent ß= 1,3
Bio-P with
RockAway
Bio-P with
AirPrex
TR (%)
€/a
€/a
€/a
€/a
€/a
29
503.953
2.585.480
0
0
3.089.433
20
0
3.176.366
0
25
0
2.537.942
314.153
150.000 3.326.366
0
2.852.095
(Niersverband, Bäckler 2012)
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 €
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P recovery – next generation
Lysotherm® - LysoPhos® = LysoGest®
optimized energy and phosphate process by separate sludge treatment
WAS
Struvit pecipitation and recycling
LysoPhos©- Process
+ Mg(OH)2
Thickening
+ NH4
Sludge dewatering
6-7% DS
Thermal Hydrolysis
Lysotherm®
(150°C, 30 Min.)
WAS digestion
Sludge water to
bio- treatment
(P- reduced)
Struvit washer
Primary sludge only
prim. sludge
digestion
www.p-rex.eu
How to increase P-recovery rate from wastewater?
Project Goals
 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
 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
 EU-wide implementation of P recovery/recycling from wastewater stream
with respect to regional conditions and demands
www.p-rex.eu
Key deliverables
 Integral guidance document and policy brief
 Technical comparison of promising, available P-recovery/recycling technologies based
on real life data (including detailed factsheets for every process, BAT)
 Environmental impact and costs of compared technologies in relation to traditional
valorization of sewage sludge and mineral fertilizers based on fossil P rock
 Agreed methodologies for LCA and LCC to be used for other projects/assessment
studies
 Stakeholder workshops (market survey and regional conditions) -> broad base input
 Educative film and summer school
 Project website and e-market for P-recycling products
(BWB)
(BWB)
www.p-rex.eu
Market issues and synergies
 Feasibility of joint application wastewater / manure? Infratructure?
 What are the real market requirements besides the legal requirements (base line)?
P recovered
LEGAL framework
Nutrient concentration
Pollutants
Plant availability
Eco-toxicity
Hygiene
Market framework
Price
Purity (MAP?)
Quantity
Shape
Handling
Operational benefits?
Consumer concerns?
www.p-rex.eu
Example: AirPrex® Berlin-Wassmannsdorf
Raw product composition
 MAP ~ 60-70%
 Moisture: 10%
 Sand and organic matter: 10%
 Approved fertilizer “Berliner Pflanze”
 Sales price depends on package size:
 The smaller the higher … (2.50€/kg)
 Challenge and potential: improvement
of yield and quality
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Outlook
 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 additinal
benefits for operator
-> still need to develop market for products (MAP, HAP etc.)
several thousand tons per year within the next 2 years
-> REACH!!!
-> whereas legal requirements are quite clear, the real end user needs are still
hidden
 If recovery >80% -> mono-incineration incl. ash treatment to obtain marketable and
useful products
 Infrastructure or technology applicable for manure?
-> what‘s better: separation and concentration of nutrients in solid phase and
then treatment of aqueous phase (or irrigation?)
-> or treatment of the manure in WWTP?
www.p-rex.eu
The Metropolitan Case Study
WASTE/
WASTEWATER
P-RECYCLING
FOOD
PRODUCT
AGRICULTURE
www.p-rex.eu
Outlook
 Still need to involve all stakeholders on equal eye level -> more efficient
collaboration, more impact -> that‘s ressource efficiency by means!
P Platform
Science
Policy
Industry
Policy
Science
Industry
Science
Industry
Policy
YES, TOGETHER
WE CAN !!!
If we want to !!!
www.p-rex.eu
Thank you for your kind attention!
Christian.Kabbe@kompetenz-wasser.de
FROM PROTOTYPE TO MARKET
PHOSPHORUS RECYCLING
www.kompetenz-wasser.de
See you there:
EU Sustainable P Conference
in Brussels 6-7th March 2013
Global TraPs World Conference
in Beijing 18-21th June 2013
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