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Frank Rogalla
Energy Potential compared to electricity consumption in wastewater Aeration
Electricity 120 g DQO/PE/d x 0,5 kwh/kg = 0,06 kwh/PE / d
Energy (Spain): 3 x 0,06 x 47 M x 365 = 3 100 M Kwh / yr
Wastewater Sludge
50 g MV / d x 47 M PE x 365 = 860 M t / yr
Biomethane CH4
0,9 Nm3 / kg MV el * 0,5 *0,65 * 10 kwh/m3= 3 kwh/kg
Total Annual Potential = 2 500 M kwh
Improving Energy Recovery in conventional WWTP High rate first stage to adsorb easily digestible organic matter
(SRT = 12 h) and improve biogas production
Maximize the efficiency of cogeneration (38 %)
Optimize activated sludge aeration for nitrogen removal, with continuous measurements of oxygen and ammonia .
Reduce the impact sludge returns
by low energy anammox process - deamonification
Reference: Wett B., Buchauer K. and Fimml C. (2007).
Energy self-sufficiency as a feasible concept for wastewater treatment systems,
Institute of Infrastructure and Environmental Engineering, University of Innsbruck, Austria.
Optimization of Conventional WWTP:
Example of plant in Strass, Austria: From 49 % energy self-sufficiency in 1995 plant achieved 108 % in 2005 Reference: Wett B. (2006). : Solved upscaling problems for implementing deammonification
of rejection water, Wat.Sci. & Tech, Vol. 53, No. 12, pp 121-128.
Anammox pilot plant in Vigo USC + Aqualia
Agujeros en las tapas
Analizador de NO2
Controlador
SC1000
Bomba vaciado
Reactor semicontinuo
2x Sondas NH4
Variador de frecuencia (agitador)
Día 23
Día 242
Primary Settler
Wastewater
Effluent
Primary sludge thickener
Anaerobic Digester
Biogas
Drum thickener
Anoxic Aerobic
Activated sludge system
Dewatering Centrifuge
Dewatered Sludge
Secondary Settler
Wastewater line
Sludge line
Pumping
Grit and grease removal
Screening
ELAN reactor
Struvite Cristallizer
Efluente Municipal Típico /PE
Value of wastewater per person equivalent (PE)
200 l x 0,5 € / m3 = 0.1 €
Organic Bioenergy 60 g DBO =
0,12 kg DQO x 0,7 x 0,35 m3 CH4/ kg
x 10 kwh / m3 CH4 x 0.1 € / kwh = 0.02 €
12 g TN x 660 €/t N= 0.008 €
2 g P x 2000 €/t P = 0.004 €
Bio-fuels: Spains annual consumption vs. total biogas potential in WW
Consumption at Gas Stations
Bioetanol 362 kt
Biodiesel 1.350 kt
Total 1.7 M t x 11.630 Kwh /t= 19 771 M Kwh/yr
Bio-methanisation
120 g DQO / P / d x 0,7 x 0,35 m3 CH4/ kg x 10 kwh / m3 CH4 = 0,5 kwh / PE / d
0,5 kwh x 47 M hab x 365 dias = 8 600 M Kwh /yr
EU FP 7 Call Biofuels from Algae
Info Day 14.11.2009
Deadline 04.03.2010
Large Scale Demo: 10 h
Full industrial plant -
from biomass production
to fuel processing
and fleet demonstration
Productivity > 90 t/ha/yr
No CO2 from fossil fuels
14 Proposals reviewed (20 submitted) = Total Cost 157 M€
21 M € for 3 shortlisted projects (50 % funding)
Kick-Off 10.05.11
Small scale facilities for PBR Evaluation
Sea water 220 L airlift tubular photobioreactor Phaeodactylum tricornutum 19.000 L oil /ha·year (Acien-Fernandez, 1998)
Sea water 110 L flat panel photobioreactor Nannochlropsis sp. 23.500 L oil /ha·year (Rodolfi et al., 2009)
Typical biomass productivity 0.035 kg m2 d1 (80 t ha1 yr1) Maximum biomass concentration 2.0 kg m3 (1.0 kg m3 typical)
Typical biomass productivity 0.050 kg m2 d1 (100 t ha1 yr1) Maximum biomass concentration 3.0 kg m3 (1.5 kg m3 typical)
Energy Requirements of PBR
750 (35 t / ha / yr)
< 10
Biomass Energy 22 kj/kg = 6 kwh /kg
Chlorella, Japan
Spirulina, CA
-carotene, Australia
Astaxanthin, Hawaii
Existing biomass production methods
Typical productivity
10 g m2 day1
(30 tons ha1 year1)
Compared to Spirulina Production
To yield 25,000 l oil/ha/year (for 25 % oil in algae)
@ cost of US$ 200/barrel = 1 € / l
(today´s oil price US$ 100/barrel):
– Productivity increase > 3 X (from 10 g/m2/d)
– Production cost decrease > 5 X (Nutrients 30 %)
40 ponds x 2900 m2 = 11.6 ha
Influent
Conventional Wastewater Treatment vs
Integration of Anaerobic Pre-Treatment
Preliminary Treatment
Primary Sedimentation
Tank
Effluent Activated Sludge
Sludge Disposal
Dewatering
Thickener
Digester
Biogas
Anaerobic Process
Biogas
Effluent Algae Pond
Dewatering
Fertiliser
Waste biomass
Disintegration of solids
New Wastewater Treatment Flowsheet ? Value Creation instead of Waste Production …
Large Scale UASB Experience
• Belo Horizonte, MG: 1,700,000 PE
• 155 000 m3/d ( first phase)
• 24 modules of 2200 m3 each
• Planned Secondary Treatment
• with Trickling Filters
Courtesy of – por gentileza de: Copasa http://www.copasa.com.br/cgi/cgilua.exe/sys/start.htm?sid=160
Integral use of biomass: A potential concept
Hidrolysis Wet
biomass Extraction Digestion
Waste biomass to boiler
enzymes solvents wastes
Aminoacids PUFA
Biomethane Upgrading
What is in Algae?
20191817161514131211109876543210
1,000,000
950,000
900,000
850,000
800,000
750,000
700,000
650,000
600,000
550,000
500,000
450,000
400,000
350,000
300,000
250,000
200,000
150,000
100,000
50,000
SP
W 0
.20
ST
H 1
00.0
0
C 1
4:0
C 1
5
C 1
6:0
C 1
6:1
C 1
8:1
C 1
8:2
C 1
9 I
S
C 2
0:3
EP
A
RT [min]
µV aw 080908 E4 methyl esters1.DATA
PROTEIN 40 %
FAT 20 %
CHO 24.4 %
FIBER 0.5 %
ASH 15 %
VITAMIN
Vit E (700 g g-1DW)
Vit C (9800 g g-1DW)
LIPID CLASSES (% TFA)
POLAR LIPIDS 50 % MGDG 15 %
DGDG 8 %
SQDG 4 %
PG 5 %
PC 7 %
PE 3 %
DGTS 5 %
PI 3 %
NEUTRAL LIPID 50 %
Algae Extraction Tests with Chlorella Vulgaris
Algae species Extraction solvent
Extraction process
Extraction condition
Total biomas extracted
%Fatty Acids /Cell Dry weight
%FA/CDW in datasheet
Fatty Acid extraction yield (%)
Chlorella V. Ethanol
Stirring 40C
2hours 10.5% 4.52 8 56.5
Chlorella V. Ethanol/ CO2
Percolation
40C 2hours 57 bar
8.5% 3.62 8 45.3
Chlorella V. Ethanol/ CO2
Percolation
40C 4hours 80 bar
8.06% 4.03 8 50.4
Chlorella V. CO2
Extraction
250 bar 0.93% 0.7 8 8.75
Laboratory and
Basic Research
Pilot 6 x 35 m2
Prototype 2 x 500 m2
Demo 10 ha
PHASE I
PHASE II
FP 7 All-gas: Step by Step Upgrading
Microalgae species
Chlorella vulgaris (SAG 211-12)
Botryococcus braunii (SAG 30.81)
Neochloris oleoabundans (UTEX-1185)
Natural Bloom river water downstream from an Urban WWTP
Culturing media
• Combo two fold (Kilham, S. S., Kreeger, D. A., Lynn, S. G., Goulden, C. E. and Herrera, L. 1998. Hydrobiologia. 377 147–159.)
Total Nitrogen: 28 mg N/L
Total phosphorous: 3,1 mg P/L
Preliminary Tests on Urban Wastewater
50 mL microalgae
inocula
1,5 L of culturing media
(WW or Combo)
Preliminary Laboratory Results for Growing Algae with Wastewater
WW DOPADA SIN
OLIGOELEMENTOS
0,0
10,0
20,0
30,0
0 50 100 150 200 250
Tiempo (horas)
mg N/l
CHLORELLA
VULGARIS
BOTRYOCOCCUS
BRAUNII
NEOCHLORIS
OLEOABUNDANS
BLOOM
WW
0,0
1,0
2,0
3,0
0 50 100 150 200
Tiempo (horas)
mg PPO43-/l
CHLORELLAVULGARIS
BOTRYOCOCCUS
BRAUNII
NEOCHLORIS
OLEOABUNDANS
BLOOM
Biomass Lipid
content
Biomass
Productivity
PBR 2000 mL flasks
Temp. 20 ± 2 ºC
10 / 14 h (D/L)
Intensity: 143 μmol m-2s-1
5% CO2 in air 1,25 L/min
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Ave
Mean Temp (oC) 12 13 15 17 19 24 25 26 22 20 15 13 18.4
Precip (mm) 50 56 68 35 16 1 1 11 12 44 82 75 451
NUTRIENT RECOVERY:
Operated with fresh water, various wastewaters and effluent from anaerobic reactors (UASB).
Pure CO2 is used as carbon source.
GROWING MICROALGAE:
Able to operate with different depths (usually 0,3 m)
Total volume in operation (6 x 9,6 = 57,6 m3).
HARVESTING TECHNOLIOGY:
Comparison of settler and DAF, with and without chemicals
Algae Biomass productivity:
Continuous mode with both WW and HRT 4 d :
Secondary and UASB: 13-Jun/25-Jul (43 days)
0
100
200
300
400
500
600
700
800
VSS
(mg
/L)
401 402 403
0
100
200
300
400
500
600
700
800
VSS
(mg
/L)
301 302 303
UASB Secondary 28 g m-2 d-1 21 g m-2 d-1
Pilot DAF: from 300…500 mgTSS/l to 4 % DS
DAF Energy = 0,1…0,05 kwh/m3 Compared to Membranes > 0,5 kwh/m3 Centrifuges > 1 kwh/m3
Initiation of the Civil works: 1st August 2013
NUTRIENT RECOVERY
Operate with wastewater and /or effluent from anaerobic reactors (UASB).
Biomass boiler will provide CO2 as carbon source, using waste materials
GROWING MICROALGAE: With depth 0,3 m, total volume in operation is 300 m3
HARVESTING : Optimised DAF; dewatering with centrifuge and solar dryer
FP 7 All-gas Demo Site: Salt Drying Beds near Chiclana.
WWTP Microalgae cultivation
13 t CO2/d ?
25 000 PE
5000 m3/d 28 mg N/L 3,1 mg P/L
3 t biomass/d
1 t biodiesel/d ?
Preliminary Balance of Wastewater Treatment with Algae Production
900 m3 /d
biomethane
Gas Driven Public Buses Madrid: 350, Barcelona: 250 Sevilla: 140, Valencia: 70 Garbage Trucks > 1000 units
750 m3 /d
biomethane
UASB
Energy Balance:
Conventional - 0,5 kwh el /m3
Anaerobic + Algae: + 3 kwh th / m3 = + 1 kwh el / m3
Preliminary Balance for Biofuel Production from Wastewater (5000 = m3/d – 25 000 PE) Biodiesel (30 % Oil ?)
1000 kg / 0,86 kg/l x 365 d/yr = 314 000 l /yr 260 cars x 6 l/100 km x 20 000 km/yr
Biomethane from Algae Residue 900 m3 CH4/d x 365 d/yr = 328 000 m3/yr x 0,65 kg/m3 = 213 000 kg CH4 /yr 213 cars x 5 kg/100 km x 20 000 km/yr
Biomethane from Raw Influent + Solids - 5000 m3/d x 500 mg/l x 0,3 m3/kg = 750 m3/d x 365 d = 274 000 m3 CH4/yr - 274 000 m3/d x 0,65 kg CH4/m3 = 178 000 kg CH4/yr - 178 cars x 5 kg/100 km x 20 000 km/yr
Biofuel Value: Methane - 0,4 €/m3 x 487 000 m3/yr = 195 000 Euro/yr Biodiesel - 0,5 €/l x 314 000 l/ yr = 157 000 Euro/yr
Water Treatment of Equivalent Value to Biofuels:
5500 m3/d x 365 x 0,2 Euro/m3 = 400 000 €/yr Reduced Energy consumption
5500 m3/d x 0,25 kwh/m3 x 365 x 0,1 €/kwh = 50 000 €/yr
Acknowledgements: Cenit Vida
Jesus Barragan and Jose Antonio Perales CACYTMAR (Centro Andaluz de Ciencia y Tecnología Marinas) University of Cádiz
Emilio Molina Grima and Gabriel Acien Dpto. Ingeniería Química, Universidad de Almería
Gracias por su atencion - Questions ?
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