doosan heavy industries & construction integrated

Integrated solutions for a better life DOOSAN SLUDGE MANAGEMENT

Doosan Heavy Industries & Construction

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION

WELCOME TO DOOSAN

Waterford WwTP

As an inevitable byproduct of municipal wastewater and many industrial processes, sludge treatment has traditionally focused on dewatering to minimize the mass of wet solids for disposal.

Increasingly, recent legislation now requires sludge to meet minimum standards for hygiene, toxicity and resuse. Additionally, the organic content of sludge is increasingly seen as a resource, either for mineral or metal reclamation or as a feedstock for anaerobic digestion, where it usually provides biogas for on-site combined heat and power generation to run the process.

The UK-based subsidiary of Doosan Heavy Industries & Construction, Doosan Enpure, provides a wide range of sludge treatment processes to meet all legislative requirements as well as maximising the amount of energy and other useful components of the sludge stream. These systems include thermal and ultrasonic pre-treatment, pasteurisation, thermophilic and mesophilic digestion, dewatering and drying.

DOOSAN SLUDGE MANAGMENT

CONTENTSWELCOME TO DOOSAN 02

TOTAL SOLUTION PROVIDER 04

WASTEWATER & SLUDGE ENERGY BALANCE 06

ADVANCED PROCESS TECHNOLOGY 07

•AnAerobicDigestion 07

•PAsteurisAtion 08

•LiquormAnAgement 09

•sonix 10

SLUDGE MAjOR REfERENCES 11

GLOBAL NETWORK 12

03

TM


TOTAL SOLUTION PROVIDER

Doosan Enpure provides total treatment solutions undertaking design, procurement,

construction, commissioning and operations for a broad range of waste or blend of wastes.

The diagram above summarizes the range of wastes that we provide treatment for and the

typical treatment method utilized.

Maximise sludge production (primary separation and high loading rates on biological reactor)

Non-biodegradable sludges (e.g. carbonate, sulphate, metal hydroxides, sulphide precipitates)

Maximise recovery of putrescible organics to maximise energy output

Pasteurisation, cell lysis (thermal hydrolysis, ultrasound, mechanical disruption, etc.)

WASTEWATER: MUNICIPAL

SOLID WASTE: COMMERCIAL

SOLID WASTE: AGRICULTURAL

WASTEWATER: INDUSTRIAL

SOLID WASTE:fOOD

SOLID WASTE: INDUSTRIAL

BIOMASS CROPS

SOU

RCES

WASTEWATER TREATMENT

WASTEWATER SLUDGE

PULP PREPARATION

PRE-TREATMENT

OUR SERVICE AREA


05

Our service areas include :

1) Process and M&E design

2) Procurement, Construction & Commissioning

3) Operation & Maintenance

4) Other: feasibility Studies, Process Audits, Project Management, Technology Licensing, System Engineering

Dewatering, drying, refining VITRIfICATION

fUEL: POWER STATION

LAND RESTORATION

LANDfILL COVER

fUEL: CEMENT MANUfACTURE

HORTICULTURE

AGRICULTURE

INCINERATION

ENERGY OUT

GAS TO GRID

DIG

ESTATE

DIGESTION

MATERIAL RECOVERY

POST-DIGESTION PROCESSING

BIOGAS

POST-TREATMENT

CONSULTING UPGRADING NEW PLANT BUILDING

Destination of digestate dictates upstream processes

Anaerobic Digestion of Sludge


WASTEWATER & SLUDGE ENERGY BALANCE

Many wastewater streams, including municipal sewage, carry chemical energy in the form of suspended and dissolved organic materials. Traditional treatment processes use energy to aerate and oxidize these organic pollutants; the process is a net energy user. However, using careful design, it is possible to make the whole process energy-neutral by minimizing the energy input to the aeration stage, maximizing sludge production and generating the required energy for aeration from the sludge. The diagrams below show the energy fluxes for two different treatment processes: a traditional extended aeration plant combined with conventional anaerobic digestion and a plant using high-efficiency primary settlement combined with high- efficiency digestion incorporating ultrasonic cell lysis (sonix™). The following table shows biogas values produced by different sludge sources.

Sludge source Generated byTonnes per year Energy value of biogas, MW

Wet mass Dry mass GrossCHP output

Electrical Thermal

Municipal sewage sludge 1,000,000 people 490,000 29,500 9.4 3.8 3.8

food waste (domestic, source segregated) 1,000,000 people 81,000 16,000 5.8 2.3 2.3

farm waste (cattle slurry) 22,000 cows 361,000 36,000 5.7 2.3 2.3

Bio energy crops (grass silage) 250 hectares 10,000 2,500 0.9 0.4 0.4

[Typical figures based on UK]

Losses from AS Plant

Energy embodied in

raw sew

age

Energy into Aeration

Energy into Aeration

83%

1%

3%

4%

16%Energy embodied in sludge

AD mixing energy input

Energy embodied in digestate

Losses from CHP

Thermal output from CHP

Electrical output from CHP

22%

100%

Losses from AS Plant

Energy embodied in

raw sew

age31% 21%

19%

Energy embodied in sludge

AD mixing + sonixTM energy

Energy embodied in digestate

Losses from AD Plant Losses from CHP

11%

100%

Extended aeration, no PSTs AD w

ithout sonixTM

AS with CAS, AD

w

ith sonixTM

Biogas

Biogas

Electrical output from CHP 16%Thermal output from CHP 18%

Losses from AD Plant

13%

6%

Digestate


ADVANCED PROCESS TECHNOLOGY ANAEROBIC DIGESTION

07

Anaerobic digestion incorporates appropriate pre-treatment, digestion and gas-handling equipment to produce raw biogas as well as solid product (digestate), which meets the most stringent requirements for use as fertilizer, soil improver or fuel.

We have experience incorporating plants with the necessary equipment such that raw biogas may be burned in a power plant (CHP) generating electrical and heat energy for export or refined to produce bio-methane for export. (I think this sentence could perhaps be reworded)

Pre-treatment (option)

Depackaging Mesophilic

CHP

Belt press

Pulping Thermophilic

Gas refining

Centrifuge

THP Suspended growth Screw press

Sonication fixed growth filter press

Screening

Organic waste and/or

sewage sludge

Anaerobic digestion

Biogas handling

Energy

Pasteurisation (option)

Dewatering (option)

To agriculture

Plant Country Sludge Process Micro Standard Digestate Use Completion Year Capacity (tDS/day)

Bellozanne STW States of jersey AD, Past E. coli - 6-log reduction Agriculture 2014 10.6

Bredbury Parkway UK AD, Past E. coli: 1000 CfU/gSalmonella absent in 25g Landfill cover 2012 61

Waterford WwTW Republic of Ireland AD, Past E. coli - 6-log reductionSalmonella absent in 25g Agriculture 2009 13.7

Sligo WwTW Republic of Ireland AD, Past E. coli - 6-log reductionSalmonella absent in 25g Agriculture 2008 10.9

Lowestoft WwTW UK AD, Past E. coli - 6-log reductionSalmonella absent in 25g Agriculture 2002 22.6

Major References


ADVANCED PROCESS TECHNOLOGY PASTEURISATION

Our system was developed specifically for sewage sludge and other biowastes undergoing anaerobic digestion. It operates with high thermal efficiency using low-grade waste energy taken typically from an associated CHP plant.

In this way, if an existing digestion plant is to be upgraded to meet the requirements of changing legislation, the pasteurisation stage can be installed without adversely affecting the existing energy balance. Alternatively, a bespoke system can be integrated into a greenfield site digestion facility to ensure that the highest overall energy recovery is obtained, maximizing revenues through the sale of energy and government green energy incentive schemes.

HOT WATER (fROM CHP OR BOILER)

HEATPASTEURISATION

(TEMPERATURE AND RETENTION AS APPROPRIATE)

HEAT RECOVERY (OPTION)

PRE-TREATED SLUDGE

COOLING WATER

HOT WATER RETURN TO CHP

COOL TO AD

COOLING WATER RETURN

Plant Country Sludge Process Completion Year Capacity (tDS/day)Reliance Street Plant

UK AD, MBR 2012 (tDS/day)

Reliance Street Plant UK AD, MBR 2012 44.7

Derwenthaugh Eco Park UK MBBR, MSW 2012 100,000

Poole STW UK SLT, MBR 2008 11.2

Cumnock STC UK AD, SLT, MBR 1998 4.675

Millbrook STC UK AD, SD, SLT, MBR 1998 40

09


ADVANCED PROCESS TECHNOLOGY LiquormAnAgement

Major References

Most sludge treatment processes result in the production of a wastewater stream, which is high in ammonia and other pollutants. The most economic way of dealing with these liquors is to return them to the inlet of the wastewater treatment works, hence their usual name, return liquors.

However, if the works is already fully loaded or is a centralized treatment facility with no associated wastewater treatment equipment, this is not an option. It is then necessary to either upgrade the wastewater treatment process or provide a stand-alone liquor treatment facility. As part of our Sludge Treatment “Start to finish” capability, Doosan Enpure offers a variety of treatment processes tailored to fit into the available space and, if appropriate, make use of existing assets. This could range from the construction of a simple stand-alone SBR to the addition of MBBR capacity to an existing activated sludge plant or provision of side-stream phosphorus recovery.

Plant Country Year Capacity (tDS/day)

Minworth WwTW UK 2007 68

Molina WwTW Spain 2006 3~4

Sagunto WwTW Spain 2006 3~4

Villanova WwTW Spain 2006 2.5~3

Alzira WwTW Spain 2005 4.5~5.5

Kavlinge WwTW Sweden 2002 4

Major References


ADVANCED PROCESS TECHNOLOGY

sonixTM is a patented technology that uses ultrasound frequencies at 20KHz to enhance energy and product recovery from organic sludge, raw material, or other solids. It maximizes gas production while minimizing sludge volume in the digestion processes, making the sonixTM technology fit well in a world where sustainability is the focus and biosolids are viewed as a valuable resource.

TM

Performance Data: •Volatilesolidsdestructionupto75%•gasproductionincreasedbyupto75%•sludgedewaterabilityincreasedbyupto15%•increaseddigesterstability•overallsolidsdestructionuptoanadditional50%

Commercial Benefits:•Approximately£1perpersoncapital•PoweroPeXcostsareapproximately20timesless

than the power produced from the biogas released•savingsfrom: - Lower disposal costs - Lower power costs - Lower chemical costs

sonixTM uses high temperatures and pressure to: •rupturecellularmaterial•solubiliseorganics•improveavailabilityofmicronutrients•reduceparticlesizes•breakdownrefractoryorganics•enhanceinteractionbetweenimmiscibleliquids•Accelerateratesofchemicalreaction

Case Study : Orange County Sanitation District, USA

•solidsdestruction:50%increase•Dewatering:10~12%increase•gasproduction:~50%increase (compared to control digester)•Payback:~2years•celllysisoftWAs*usingsonixTM

Before sonixTM

After sonixTM

*tWAs:thickenedWasteActivatedsludge

Plant Country Sludge Process Completion Year Capacity (tDS/day)Bellozanne STW

State of Jersey AD, Past 2014 (tDS/day)

Bellozanne STW States of jersey AD, Past 2014 10.6

Reliance Street Plant UK AD, MBR 2012 44.7

Brighton & Hove WwTW UK AD 2012 47

Esholt WwTW Digestion Plant UK AD 2009 34.1

jebel Ali Thermal Sludge Dryer UAE SD 2009 70.8

Ringsend WwTW Republic of Ireland THP, AD 2009 56(extension), 120(total)

Waterford WwTW Republic of Ireland Past, AD 2009 13.7

Sligo WwTW Republic of Ireland Past, AD 2008 10.9

Colchester Thermal Sludge Dryer UK SD 2002 13.7

Lowestoft WwTW UK Past, AD 2002 22.6

Bromborough WwTW UK BAff, AD 2000 37.4

Pyewipe STC UK Past, AD 1999 39.7

Truro Newham Sludge Stage 2 UK DH 1998 1.7

cliffquaystW(ipswich) UK AD, Past 1997 19.5

Harwich & Dovercourt STW UK ASP, Past, AD 1997 4

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sLuDgeProJecteXPerience

Major References

Major Processes

Our experience extends to more than 50 sludge management projects with various sludge processes.

Abbreviations•AD:AnaerobicDigestion•AsP:ActivatedsludgeProcess•bAFF:biologicalAeratedFloodedFilter•cHP:combinedHeat&Power•DH:Dehydrate•tHP:thermalHydrolysisProcess•Past:sludgePasteurisation•sD:sludgeDrying•sLt:sludgeLiquortreatment

Thickening

Dewater

Drying

Pasteurisation

AD

sonixTM

Thermal

CHP

Odour

Number of Major Sludge Projects by Category

32

26

8

27

24

13

8

25

1

CORPORATE NETWORK

Overseas Subsidiaries

DOOSAN ENPUREBirmingham, UK

DOOSAN HYDRO TECHNOLOGYTampa, USA

DOOSAN POWER SYSTEMSCrawley, UK

DOOSAN POWER SYSTEMS INDIAHaryana, India

DOOSAN POWER SYSTEMS (EUROPE) Ratingen, Germany

DOOSAN POWER SYSTEMS (NORTH AMERICA) Atlanta, USA

DOOSAN POWER SYSTEMS (LATIN AMERICA) Sao Paulo, Brazil

DOOSAN BOBCOCK Renfrew, UK

SKODA POWER Plzen, Czech

DOOSAN CHENNAI WORKSChennai, India

DOOSAN HF CONTROLS Carrolton, USA

DOOSAN IMGB Bucharest, Romania

DOOSAN ENGINEERING & SERVICESMontvale, USA

DOOSAN VINA Dung Quat, Vietnam

DOOSAN VINA HAIPHONG Haiphong, Vietnam

HANJUNG POWER NCD, Papua New Guinea

DOOSAN LENTJES Ratingen, Germany

Overseas Branches

AMERICAS

SANTIAGO OFFICESantiago, Chile

DOOSAN HEAVY INDUSTRIESAMERICA New jersey, USA

PITTSBURGH OFFICECranberry, USA

SCHENECTADY OFFICE Schenectady, USA

NEWINGTON OFFICE Newington, USA

TAMPA R&D CENTER Tampa, USA

ASIA

BEIJING OFFICE Beijing, China

NEW DELHI OFFICE New Delhi, India

DOOSAN HEAVY INDUSTRIES JAPANTokyo, Japan

BANGKOK OFFICE Bangkok, Thailand

HANOI OFFICE Hanoi, Vietnam

JAKARTA OFFICE Jakarta, Indonesia

MUMBAI OFFICE Mumbai, India

SHANGHAI OFFICE Shanghai, China

TAIPEI OFFICE Taipei, Taiwan, R.O.C.

EUROPE

FRANKFURT OFFICE Frankfurt, Germany

BIRMINGHAM R&D CENTERBirmingham, UK

MIDDLE EAST & AFRICA

RIYADH OFFICE Riyadh, Saudi Arabia

KUWAIT OFFICE Salmiya, Kuwait

DUBAI OFFICE Dubai, UAE

ABU DHABI OFFICE Abu Dhabi, UAE

MIDDLE EAST OPERATIONS CENTERDubai, UAE

NORTH AFRICA OFFICE New Cairo, Egypt

DAMMAM R&D CENTER Al Khobar, KSA

>

Doosan Heavy Industries & Construction Doosan Enpure Ltd.

UK OFFICEECIFFO LUOESDoosan House, Parklands Business Park, Rubery,029-731 edoC liaM

465 Gangnam-daero, Seocho-Gu, Seoul Korea Birmingham, United Kingdom, B45 9PZTel. +82-2-513-6114 Fax. +82-2-513-6200 Tel. +44-121-683-2800 Fax.+44-121-683-2888www.doosanheavy.com www.doosanenpure.com

[as of May 2015, 3th Edition]

WATER NETWORK

SEOUL WATER HQ

SubsidiariesBranch Offices

DOOSAN ENPUREBIRMINGHAM R&D CENTERDoosan HouseParklands Business ParkRubery, BirminghamWest Midlands B45 9PZ, UKTel +44-121-683-2800Fax +44-121-683-2888

DOOSAN HYDRO TECHNOLOGYTAMPA R&D CENTER9208 Palm River Road, Suite 302 Tampa, FL 33619Tel +1-813-579-3049Fax +1-813-623-6666

SANTIAGO OFFICENueva Tajamar 481 Oficina 1103, Las CondesSantiago, ChileTel +56-2-657-3333Fax +56-2-657-3343

HEAD OFFICE & CHANGWON PLANT22 Doosan Volvo-roSeongsan-Gu, Changwon Gyeongnam 642-792, KoreaTel +82-55-278-6114, 7114 Fax +82-55-264-5551~2

DOOSAN VINADung Quat Economic Zone Binh Thuan, Binh Son Quang Ngai, VietnamTel +84-55-361-8900Fax +84-55-361-8950

NEW DELHI OFFICE515, Fifth Floor, Time Tower MG Road Gurgaon, 122002Haryana New Delhi, IndiaTel +91-124-665-3361Fax +91-124-665-3345

RIYADH OFFICEOffice No. 205 & 206, The Plaza Building (Akariya No.4)Olaya Street, P.O.Box 9656 Riyadh 11423, Saudi ArabiaTel +966-1-419-1696Fax +966-1-419-1995

DAMMAM R&D CENTERAl Turki Business Park 9th Floor Al Khobar 31952, Eastern ProvinceSaudi ArabiaTel +966-3-868-6951Fax +966-3-868-7100

KUWAIT OFFICEP.O. Box 2031, Mishref 40171Office No. 7B, Block 4Laila Tower, Salem Al-Mubarak StreetSalmiya, KuwaitTel +965-2573-3127Fax +965-2575-2001

DUBAI OFFICEMonarch Office Tower, 30th FloorSheikh Zayed Road, P.O. Box 11859 Dubai, UAETel +971-4-327-5545Fax +971-4-327-55291

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