Quantity, Quality and Market aspects of potential P recycling routes in Europe

Christian Kabbe

Berlin Centre of Competence for Water

Wageningen, 6th February 2013

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www.p-rex.eu

Phosphorus – bottleneck of life

www.p-rex.eu

Limited availability Strategic resource

„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)

- Wastewater/sewage sludge - Biowaste - Manure - Meat and bone meal

The traditional, closed anthropogenic P cycle

www.p-rex.eu

Once upon a time, there was an unbroken circle …

http://www.nhm.ac.uk/research-curation/research/projects/phosphate-recovery/ceep11.htm

Soil <-> life balance …

The modern anthropogenic P „cycle“

www.p-rex.eu

Disruption of P cycle: Urbanization Industrialisation Globalisation

Problems: - Discoupling of food production and consumption - Pollutants/contamination - Inefficient use

Challenges for the future: - Increasing P demand - Decreasing quality of fossil P rock - Limited availability - Separation of nutrients from pollutants for recycling

Need of mineral fertilizer to compensate losses!

EU needs to import 975,000 t of mineral P!!!

http://www.nhm.ac.uk/research- curation/research/projects/ phosphate-recovery/ceep11.htm

Building Bridges!

EU FP7 Project

Sustainable sewage sludge management fostering phosphorus recovery and energy

efficiency

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Closing the loop, but where and how?

www.p-rex.eu

amended from: http://www.nhm.ac.uk/research-curation/research/projects/phosphate-recovery/ceep11.htm

210 Mt P rock (global mining 2012, USGS 2013)

90%

10%

Germany‘s National P Reserves

www.p-rex.eu

Waste stream Quantity of waste

stream

P-Reserve

(theoretical)

Compared to

Pmineral imported

~ 120.000 t/a

wastewater

(municipal) ~ 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 %

animal excreta

manure: ~ 190 Mio m3/a

~ 240.000 t P/a Completely but not

efficiently used! solids: ?

6% of German cropland (12 million acres) short of P, whereas NS and NRW have surplus sufficient for 1 million acres from manure (Römer et. al. 2013)

(Different sources DESTATIS)

,0

200000,0

400000,0

600000,0

800000,0

1000000,0

1200000,0

1400000,0

1600000,0

1800000,0

2000000,0

2200000,0

1998 2001 2004 2007 2008 2009 2010 2011

se

wa

ge s

lud

ge

in

me

tric

to

ns d

ry m

att

er

thermal agriculture landscaping landfill other interim storage

Sewage sludge routes in Germany

www.p-rex.eu

(DESTATIS 2012)

55%

3%

13%

29%

Obviously: insufficient reuse of P

Sewage sludge routes in Europe 2010

www.p-rex.eu

(DESTATIS 2012)

Obviously: insufficient reuse of P

0

250000

500000

750000

1000000

1250000

1500000

1750000

2000000

AT BE BG CY CZ DE DK EE ES FI FR GR HU IE IT LT LU LV MT NL PL PT RO SE SI SK UK CH

other

landfill

application to land

incineration

Dry

ma

tte

r in

me

tric

to

ns

European total quantity: ~ 11 million tons sludge (dry matter)

WATERLOOP – Trinity of P Recycling

www.p-rex.eu

Food

Humans

Wastewater

WWTP

Agriculture

Sewage sludge D

ire

ct a

pp

licat

ion

o

n a

rab

le la

nd

P r

eco

very

fro

m

aqu

eo

us

ph

ase

(M

AP

)

P r

eco

very

fro

m

inci

ne

rati

on

ash

EU: 11 million tons of sludge dry matter/a ~ 350,000 t P/a

P

Global P recycling from wastewater: End of 20th century only 30%! (Liu et al. 2008)

Hot spots for P recovery in WWTP

www.p-rex.eu

(amended from Montag 2010)

Some P recovery processes in Europe

www.p-rex.eu

PEARL MAP FULL

Ash

Sludge

Sludge Liquor

LEACHPHOS P-mineral DEMO

Thermal

Leaching

P-bac (INOCRE) MAP

PHOSTRIP MAP, CaP DEMO

P-RoC CaP/CSH DEMO

PASCH CaP

MEPHREC P-slag DEMO

SEPHOS AlP

LYSOGEST MAP Full

Electrochemical MAP, CaP

PRISA MAP

Gifhorn MAP, CaP DEMO

AirPrex MAP FULL

NuReSys MAP FULL

Stuttgart MAP DEMO

THERMPHOS P4 FULL

AshDec (SUSAN) P-mineral DEMO

RECOPHOS D P-mineral DEMO

SESAL-PHOS CaP

KREPRO FeP FULL

Budenheim CaP DEMO

RECOPHOS AT H3PO4 DEMO

Crystalactor MAP, CaP FULL

Aqua Reci H3PO4

?

FIX-PHOS CaP/CSH DEMO

PHOXNAN H3PO4

REPHOS MAP Full

Wet Oxidation

With Leaching

Low Chemicals Demand

P recovery units - sludge

www.p-rex.eu

Process Operator/location Scale Output Contact

P recovery from sludge

AirPrex Waßmannsdorf (DE)

BWB full MAP

Berliner Pflanze

BWB

Dr. B. Heinzmann

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. Müller-

Schaper

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

P recovery units – process water

www.p-rex.eu

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

MAP

Crystal Green™

OSTARA

Jim Hotchkies

NuReSys

(prototype) Dairy processing (BE) full

MAP BIOSTRU

NuReSys

Dr. Wim Noerman

NuReSys Potato processing (BE) full MAP

BIOSTRU

NuReSys

Dr. Wim Noerman

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

Process Operator/location Scale Output Contact

P recovery during or after incineration

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

P recovery units – during or after incineration

www.p-rex.eu

Undiluted incineration -> ash

Highest recovery potential (> 90% P compared to influent)

Wh

at a

bo

ut

Aq

uaf

in a

nd

Eco

Ph

os?

P recovery - feasibility

www.p-rex.eu

dry matter

content after

deatering

cost Fe-saltdisposal cost

sludge

opex Air-

PrexRockAway total cost

TR (%) €/a €/a €/a €/a €/a

Fe-salt 20 g/m³

Influent ß= 1,329 503.953 2.585.480 0 0 3.089.433

Bio-P with

RockAway20 0 3.176.366 0 150.000 3.326.366

Bio-P with

AirPrex25 0 2.537.942 314.153 0 2.852.095

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 €

The practical example of WWTP Neuwerk (Niersverband):

(Niersverband, Bäckler 2012)

P recovery – next generation

www.p-rex.eu

WAS

Thickening 6-7% DS

Thermal Hydrolysis

Lysotherm®

(150°C, 30 Min.)

Struvit pecipitation and recycling

LysoPhos©- Process

+ Mg(OH)2 + NH4

Sludge dewatering

Sludge water to

bio- treatment

(P- reduced) Struvit washer

prim. sludge

digestion

WAS digestion

Primary sludge only

Lysotherm® - LysoPhos® = LysoGest® optimized energy and phosphate process by separate sludge treatment

How to increase P-recovery rate from wastewater?

www.p-rex.eu

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

Project Goals

EU-wide implementation of P recovery/recycling from wastewater stream with respect to regional conditions and demands

Key deliverables

www.p-rex.eu

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)

P recovered P recovered

Feasibility of joint application wastewater / manure? Infratructure?

What are the real market requirements besides the legal requirements (base line)?

Market issues and synergies

www.p-rex.eu

P recovered

LEGAL framework Nutrient concentration Pollutants Plant availability Eco-toxicity Hygiene

Market framework Price Purity (MAP?) Quantity Shape Handling Operational benefits? Consumer concerns?

Example: AirPrex® Berlin-Wassmannsdorf

www.p-rex.eu

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

Raw product composition

Outlook

www.p-rex.eu

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?

The Metropolitan Case Study

www.p-rex.eu

WASTE/

WASTEWATER

P-RECYCLING

PRODUCT

AGRICULTURE

FOOD

Outlook

www.p-rex.eu

Still need to involve all stakeholders on equal eye level -> more efficient collaboration, more impact -> that‘s ressource efficiency by means!

Science Policy Industry

Policy

Science

Science

Industry

Industry

Policy

YES, TOGETHER WE CAN !!!

I f w e w a n t t o ! ! !

P Platform

Thank you for your kind attention!

Christian.Kabbe@kompetenz-wasser.de

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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www.p-rex.eu