integrated gasification and nutrient recovery from waste ... · integrated gasification and...

Integrated Gasification and NutrientRecovery from Waste Biomass

VETAANI Project Seminar, Helsinki09.04.2014

Ludwig Hermann, Stefan Krech

© Outotec – All rights reserved

Agenda

1. Introduction to Outotec2. Technology and expertise3. Motivation4. Resources & processes5. Challenges6. Product characteristics

Apr 2014 Vetaani Project Seminar - Integrated Gasification & Nutrient Recovery2

89%of the order

intake,Environmental

Goods andServices, OECD


Technology leader for over a century


Year

2013

2010

2006

2001

1990

1970

1950

1900

Listing on the Helsinki Stock Exchange

BOLIDEN CONTECH

OUTOKUMPU TECHNOLOGY

LURGIMETALLURGIE

OUTOKUMPU

NORDBERG GRINDING MILLS

KHD ALUMINIUMAISCO, SUPAFLO

WENMEC

LAROX

AUSMELT

ENERGYPRODUCTSOF IDAHO

SCANALYSEBACKFILL SPECIALISTS

TME Group, DEMIL MANUTENÇAONUMCORE

KILN SERVICES, VPFMILLTEAM, EDMESTON

AUBURN

ASH DEC


Outotec by the numbers (2012)

• Sales EUR 2,087 million withEUR 476 million generated byservices

• 18 competence centers, presence in26 countries, deliveries to 80 countries

• Over 4,800 professionals• Extensive IPR portfolio

• Over 5,700 national patents/applications,630 patent families and 70 trademarks

• R&D expenditure EUR 42 million

• Market capitalization ~ EUR 2.0 bn• Listed on NASDAQ OMX Helsinki


Sales

366 426556

740

10001218

878970

1386

2087

0200400600800

1000120014001600180020002200

EUR million

Operating profit**

*) Combined basis, **) excl. One-time items and PPA amortizations

8 1124

52

96

120

5975

121

194

020406080

100120140160180200220


Our long-term customers


Major global mining companies Intermediate sized companies

Selected reference customers of Outotec



Technology & expertiseTechnology & expertise


A snapshot of our benchmark technologies

• Half of the world's pyrometallurgicalprimary copper is produced withOutotec® Flash Smelting

• One-third of the world’shydrometallurgical copper isproduced with Outotec® SX-EW

• Over one-third of the world’s sulfuricacid capacity runs on Outotectechnology

• Most of the world's iron ore pelletsare produced using Outotec'straveling grate process



Solutions for phosphate mining & processing

• Mining solutions• Beneficiation solutions including gravity

separation, flotation and comminution

• Sulfuric acid plants• World’s largest sulfuric acid plants have

been built by Outotec• Highest energy efficiency for steam and

electricity generation

• Calcination plants• Calcination with multiple energy recovery

stages for high impurity ores may includecadmium removal

• Services• Vanadium catalyst screening



Fluidized bed based processes


Incineration - gasification


Agenda

1. Introduction to Outotec2. Technology and expertise3. Motivation4. Resources & processes5. Challenges6. Product characteristic


2014 Outotec ranked3rd most sustainable

of all listed companies ofthe world!Corporate Knights,

World Economic Forum Davos 2014



Source: Jensen, L.S., 2012

Manure + sludge = source of over-fertilization


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


Agenda

1. Introduction to Outotec2. Technology and expertise3. Motivation4. Resources & processes5. Challenges6. Product characteristic



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

Plug-Flow

digestion

Biogas (SNG/LNG)

II.De-

watering

III.Drying

IV.Thermal

Conversion

V.Ash

processing

K + PKstruvite

SNG, steam,electricity

Secondaryresidues

Raw materialP(K)Fertilizer

ASH DECProcess

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

7-8%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


High efficiency drying – closed loop steam dryer


RTD Project DEBUGGER:Energy efficient steam dryer,

<400 kWh /t H2O


Cattle manure to energy – Hereford (Tx)


The multi-fuel Outotec Energy Products system is designedto convert 420.000 tons of cattle manure a year into energyfor an ethanol plant.


Sewage sludge to energy – State Zürich facility


Converts 100.000tonnes per year ofdewatered sludgefrom Zürich Stateto 7’000 MWh/yelectricity and35’500 MWh/y todistrict heating.

Designed and engineered for downstream phosphorus recovery!

93.9% of Zürich’s population votedin favor of new mono sewage sludgeincinerator in a referendum!


Animal by-products to energy, High River (AB)Cargill MeatSolutions, HighRiver, Alberta,Canada


Conversion of 200‘000 tpy animal by-products to 400°C, 45bar superheated steam


Double CFB steam gasification


GasificationT = 750 °C – 900 °C

RegenerationT = 850 °C – 950 °C

Ash

Ash

fuel

H2O (g)

(fuel)

air

silica sand(ash)

silica sandchar

H2O, H2, CO2,CO, CH4

(CxHy, Tar)

N2, CO2, O2,H2O (g)

(SO2, NOx)


20 kWth dual fluidized bed facility, IFK Stuttgart University

- gasifier- bubbling bed reactor- diameter: 150-200 mm- height: 3 m

- regenerator- turbulent reactor- diameter: 70 mm- height: 12 m

- bed material: silica sand- gas analyses

- gasifierH2, CO, CH4 O2, CO2, CxHy

- regeneratorCO, O2, CO2, SO2, NOx

- electrical heating- volumetric fuel dosing



First DFB steam gasification results (D. Schweitzer)

• DFB experiments at the 20 kWth test facility• with a maximal fuel particle size of < 2 mm, the occuring ash clusters had

no effect on the process• stable conditions for several hours were achieved

steam gasification of sewage sludge is possible

• First results indicate a promising behaviour• relatively high gas yield of 0.83 m³/kgfuel, daf• gas yield and energy output of sewage sludge slightly lower than for

wood


Fuel Tin °C

S/C ratioin molH2O/molC

Gas yieldin m³i.N.,dry/kgfuel, daf

Energy outputin MJ/kgfuel, daf

LHV syngasin MJ/m³i.N.,dry

Sewagesludge

775 1.57 0.83 10.8 13

Wood 760 1.74 0.95 12.2 12.8

Source Stuttgart University, IFK institute


Biogas from biomass/RDF: Cemex Rüdersdorf


Design data:

Thermal capacity: 100MWFuels: Carbonic ashes, biomass, RDFProduct gas: 60000 Nm³/h, 3-5.3 MJ/Nm³, 860-920°CAsh: <1% carbon

Calciner

Rotary kiln burner

Source Cemex, Rüdersdorf


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• Alkaline phosphate compounds available to crops


Fließbild – Schlammverbrennung + ASH DEC


Process flow diagram100‘000 tonnes sewagesludge incineration

Sludge & manure incineration



ASH DEC as an integrated part of biomass incineration

Ash from hot gas cyclonePre-heating of additives

Calcining in the rotary kilnMetal separation in hot gas filter

Flue gas cleaning in the SSI


Various fertilizer options downstream

Example: production of NPKfertilizers from AN, SOP andtreated ash, scale 12 tph, atLonza AG; Visp, Switzerland



Agenda

1. Introduction to Outotec2. Technology and expertise3. Motivation4. Resources & processes5. Challenges6. Product and ecological footprint


Source PSI, Villigen


Build a closed-loop nutrient ecosystem


150.000 MWh/yearBiogas, Electricity &

Heat

1 Mt/yearmanure

30.000 tpyFertilizer


Challenges

• Cooperation of/with livestock farmers to attain• Long-term, reliable supply of raw material

• Supply of >100’000 tonnes dewatered manure for one plant

• Effective nutrient separation and recovery in upstreamprocesses (N recovered as ammonium sulfate instead ofbeing lost during high temperature conversion)

• Efficient on-site use or subsidized sale of generated energy(biogas and/or electricity value > € 100/MWh)

• Foreseeable and favorable regulatory framework

• Comparatively high investments



Agenda

1. Introduction to Outotec2. Technology and expertise3. Motivation4. Resources & processes5. Challenges6. Product and ecological footprint



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


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TMEr

trag

[g]

Yield (DM)

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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P-uptake

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Energy footprint of fertilizer processes

7,14

22,72

16,78

5,25

61,16

55,46

0

10

20

30

40

50

60

70

Single superphosphate Acidulated sludge ash Calcined phosphate

GJ/

tP2O

5

Cumulated energy balance

Energy Consumption Energy Generation



Comparative pollutant concentrations



Tentative GaBi footprint for ASH DECCO2 from organic renewable resource neglected


GWP 0,65 kgCO2-Equiv.


Conclusion

• Because of water quality concerns, continued buildup of soil P levels due to

land-applied manure and litter will not be a long-term option in most livestock

farming areas.

• Energy recovery (biogas, electricity and/or process steam) with ash export is a

promising high-volume alternative use for farmyard manure and poultry litter.

• Because of nutrient concentration and value in the ash, energy options provide

a built-in mechanism for economically exporting surplus P and associated

nutrients out of livestock farming areas.

• In fact, the economic viability of energy options depends on being able to

market ash for use in fertilizers outside concentrated livestock areas.

• No pathogens and odors in ash




Thank you for your attention!

[email protected]@outotec.comwww.outotec.com Source: The Guardian


Backup



Executive summary

• Phosphate recycling is necessary for long term feed and food security• Farmyard manure and sewage sludge present a large potential for

energy and phosphate recovery

Outotec could provide a complete value chain solution for energy &phosphate recovery if• Drying efficiency can be significantly improved to generate net

revenues from energy conversion• Ash can be processed to phosphate fertilizers with profit by lowering

the production cost and increasing the product value• The supply and distribution chains can be closed by setting up

symbiotic co-operation between stakeholders• A supportive legal framework is enforced


integrated gasification and nutrient recovery from waste ... · integrated gasification and...

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