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Integrated Energy Generation & Nutrient Recoveryfrom Sewage Sludge and Farmyard Manure

Ludwig Hermann

National Reference Group MeetingPROMISE

Braunschweig, 14. October 2014

© Outotec – All rights reserved

Agenda

• About Outotec

• Challenges

• Biomass Resources andConversion Processes

• P-rich Ashes and RecoveryProcesses

• Product Evaluation

• Marketing and Sales Options

11/11/2014 Bonus Promise NRG Meeting - Energy & Nutrient Recovery fm Sewage Slugde & Manure2


Outotec in brief

• Outotec provides leading technologies andservices for the sustainable use of Earth’snatural resources

• As the global leader in minerals and metalsprocessing technology, we have developed manybreakthrough technologies over the decades forour customers in mining and metals industries

• We also provide innovative solutions for industrialwater treatment, the utilization of alternativeenergy sources and the chemical industry

• Outotec shares are listed on NASDAQOMX Helsinki



A century of accumulated expertise



Local operations, global presence

Wide supplier network with established long-term relationships


R&D, salesand servicecenters in

27countries

Deliveries tomore than

80countries Experts of

over

60nationalities Outotec R&D, sales and service centers

Outotec manufacturing/assembly

Sales

1.9bnEUR in 2013

4,855employees

in 2013


Agenda

• About Outotec

• Challenges







Source: Schoumans, O., 2014

11/11/20147 Bonus Promise NRG Meeting - Energy & Nutrient Recovery fm Sewage Slugde & Manure

Olsen P-concentration categories of cropland soils inthe EU 2009-2012


Ecological water quality status in EU memberstates (Amery, F. and Schoumans, O., 2014)



We need to carry the nutrients to places where weneed them and not use them where they are excreted!



Agenda

• About Outotec

• Challenges







Manure140 Mt DM5 Mt P2O5

Sewage sludge12.5 Mt DM

750,000 t P2O5

Animal by-products cat. 1

1.5 Mt DM450,000 t P2O5

AnaerobicDigestion

Biogas (SNG/LNG)

II.De-

watering

III.Drying

IV.Thermal

Conversion

V.Ash

processing

N + Kstruvite

SNG, steam,electricity

Secondaryresidues

Raw materialP(K)Fertilizer

ASH DECProcess

Process steps necessary to obtain ash as a phosphateconcentrate for transportation and further processing

6-8%DM

25-30%DM

45-95%DM

Renewable energy yield (technical potential) of EU28 manure:583 TWh (2,100,000 TJ) = 3-5% of total European energy supply

Relevant secondary P-flows in the EU28

Resources & recovery processes


NAmmonium-sulfate

Ash asRaw material

100%DM



Efficient drying: Closed Loop Steam Dryer, Storuman, S• 128,000 t/y bio-pellets• 64,000 MWh/y electricity• 112,000 MWh/y district heating


Phosdryer development and pilot plant


RTD Project DEBUGGER: Energy efficientsteam dryer, 400 kWh /t H2O


Fluidized bed based processes


Incineration - gasification


The key to over-fertilization is P-concentration!


If you have too much phosphorus-rich waste and not enoughcropland nearby – consider incineration!

=Concentration

• 1,5 t P2O5 1,5 t P2O5

Gasification



Thermal conversion I: Sludge-to-EnergyZürich Werdhölzli, 100.000 t/y sewage sludge

8.000 MWh/y electricity, 35.500 MWh/y district heating


Thermal conversion II: Manure-to-Energy, Hereford, Texas420,000 t/y cattle manure, 840,000 MWh/y steam, 30 bar, 385°C

17 11/11/2014 Bonus Promise NRG Meeting - Energy & Nutrient Recovery fm Sewage Slugde & Manure



Thermal conversion III: Animal By-products-to-Energy, High River,Alberta; 200,000 t/y to superheated steam, 45 bars, 400°C



Thermal Conversion IV: Biomass-to-Syngas:Cemex Rüdersdorf, mixed fuels 100 MW gasifier, 60,000 Nm³/h

syngas for cement kiln


Agenda

• About Outotec

• Challenges







Ash physical and chemical properties

• Ash is a mineral phosphate concentratewith more or less impurities & pollutants,depending on the feedstock!

• Like rock, ash is not afertilizer!

• Ash needs processing to becomebecome a fertilizer!



Biomass ash vs. rock phosphate concentrate


1) Kley, G., 2004 2) http://www.biodat.eu/

Ash may beappropriate forreplacement of rockphosphate concentratein conventional BATfertilizer processes


Biomass ash vs. rock phosphate concentrate


1) Kley, G., 2004 2) http://www.biodat.eu/

ASH DEC hasbeen speciallydesigned tocope withimpurities andpollutants!


The ASH DEC Process


• Concentrating nutrients• Removing pollutants; HM = arsenic, cadmium, lead• Sodium phosphates (CaNaPO4) available to crops



Product conversion: Ash-to-Fertilizer pilot productionContinuous treatment of 7 t/daysludge ash, facility fully processcontrolled.


Product finish: NPK large scale test productionExample: production of NPKfertilizers from AN, SOP andtreated ash, scale 12 tph, atLonza AG; Visp, Switzerland



Agenda

• About Outotec

• Challenges







Corn pot test (M. Severin et al. 2014)


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Sandy soil 1,14 mg P/100g soil, pH 7,0 after neutralization with lime, Mitscherlich-pot 6 kg/pot, 9 corn cropsFertilizing in 3 steps (0,176; 0,352 and 0,528 g P per pot)

Dry

mat

tery

ield

(g)


Corn pot test (M. Severin et al. 2014)


Sandy soil 1,14 mg P/100g soil, pH 7,0 after neutraiization with lime, Mitscherlich-pot 6 kg/pot, 9 corn cropsFertilizing in 3 steps (0,176; 0,352 and 0,528 g P per pot)

P-Aufnahme

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Tentative GaBi footprint for ASH DECCO2 from organic renewable resource neglected


GWP 0,65 kgCO2-Equiv.


Comparative pollutant concentrations



Agenda

• About Outotec

• Challenges







Market history• Historically, phosphate fertilizers were produced by one of

two routes: The wet chemical or the thermal fertilizerprocessing route

• After both routes having been equally important in the firsthalf of the twentieth century, the wet route has prevailed,leaving no more than 1 Mt of P2O5 processed in furnaces,mainly because of• Plenty of cheap sulfur supply• Relatively high energy cost• Cheap waste discharge in most processing countries• Processing phosphates to phosphoric acid produces 5 tonnes of

waste per tonne of product (P2O5).

• Today, industry, traders and farmers prefer water soluble,high analysis fertilizers



Critical question: Are the dominating products the bestoptions for today’s soils and crops?

11/11/201434Source: Felda Agricultural Services

Bonus Promise NRG Meeting - Energy & Nutrient Recovery fm Sewage Slugde & Manure


New complex fertilizers from recoveredphosphates

Struvite NPK 6:28:0 + 10 Mg crystals• White crystals and high in nutrients (34% NP + 10%

Mg) for transport & efficient handling• Very low pollutant concentrations• The clean, inorganic product is suitable for blending.

NPK 16:8:0 + 5S granules (AN + calcined P)NPK 23:8:0 + 5S granules (Urea + calcined P)• Low pollutant concentrations• Calcined, alkaline phosphates + Urea for acidic soils

What are the most beneficialapplications of these products?


Sources: NuReSys, ASH DEC


Thank you for your attention!

This presentation contains material from PROMISE and otherEuropean R&I Projects.PROMISE has received funding from BONUS (Art 185) fundedjointly from the European Union’s Seventh Programme forresearch, technological development and demonstration, andfrom Baltic Sea national funding institutions.

[email protected] www.outotec.com

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