The Biobed® Advanced system is cheaper and more reliable

Biobed® SMART and Memthane®

Novel Reactors and their superior control

Lyon; November 27, 2012; 13:45 Jan Pereboom

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Contents

1. Introduction

2. The Biobed® Advanced granular system

3. The Biobed® SMART reactor control system

4. The Memthane® AnMBR

5. Conclusions

Biothane: competence centre of Veolia Water

Veolia Water • Revenues 12.6 bln€; 69 countries; 97,000 employees (2011)

• Drinking water for 103 mln consumers; sewage of 73 mln inhabitants

Veolia Water Solutions and Technologies (VWS) • Contracting and equipment; 350 proprietary technologies

• Revenue 2.3 bln€; 135 business units; 10,800 employees

Biothane • World market leader for Anaerobic industrial wastewater treatment

• In 35 years more than 530 references were established

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Anaerobic versus Aerobic WWT

45% Carbon Dioxide

50% Biomass

BOD Air (O2)

100 kg COD to Aerobic

BOD (25OC – 35OC)

75% Biogas (75% Methane)

5% Biomass

100 kg COD to Anaerobic

Aeration

(100 kWh)

Sludge, 30-60 kg

Heat loss

2-10 kg COD

CH4 26 - 30 Nm3 CO2 5 - 12 Nm3

Sludge, 5 kg

10-20 kg COD

1 kg COD removed 0.35 Nm3 CH4 or 3.8 kWh

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Biothane’s Granular Technologies

Biobed® Advanced UASB or EGSB • Granular Sludge Bed

• Up to 30 kg COD/m3/d

Biobed® Modular Plant • Compact off-site construction

• 50 ~ 200 m3 reactor volume

• 0.5 ~ 4.0 tCOD/day

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Biothane technologies; non-granular Biobulk CSTR • Solid waste digestion

• With or without sludge recirculation

• Suitable for high COD / SS / FOG waste(water)

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Upthane™ • Municipal UASB technology for

tropical climates

• Novel design

Memthane® Anaerobic MBR • New technology for high strength wastewater

• Using Cross-flow UF membranes

• High COD / SS removal efficiencies

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Pomethane® CSTR • Palm Oil Mill Effluent

Biothane UASB vs. Biobed® EGSB

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Upflow Anaerobic Sludge Blanket • 10 ~ 15 kgCOD/m3d; 8 ~ 10 meter height

Expanded Granular Sludge Bed • 15 ~ 25 kgCOD/m3d; 10 ~ 20 meter height

500 references

COD reduction rate EGSB is equal or lower but

Volumetric loading rate is 2-3 x higher

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Biothane UASB Biobed® EGSB

Biothane UASB vs. Biobed® EGSB

Biobed® Advanced Anaerobic granular technology at the next level

Reduced investment and operating costs

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Combining the best of both

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Solution Biobed® Advanced

Advantages of UASB

Advantages of EGSB

Challenge: combining the best of UASB and EGSB

• Excellent performance • High COD removal efficiency • Good biomass inventory

• Reduced investment costs • Higher volumetric loading rates (2-3 times) • Taller reactors (2-3 times) • Smaller footprint

Objectives of Biobed® Advanced & SMART

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80 %

hydraulicbuffer tank

Anaerobic reactor

Aeration tank

Hydraulic buffer tank

Anaerobic reactor

Aeration tank

Dynamic control

85 % 10 ~ 25% smaller

Improving the anaerobic performance • Thus reducing investment and operating costs

Improving COD removal rate

Novel Biobed® Advanced Settler

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Patented new settler and reactor design

Multi level biogas separation

TTS; Tilted Tube Separator on top of the settler • Increasing the settler surface area for

• Improving the retention of biomass and SS in the reactor

Robust effluent pipes which replace conventional effluent gutters

Based on fundamental research

5 years research by committed team • Many with more than 25 years of experience

Lab scale testing

Hydraulic model testing at 1:1 scale

Pilot scale testing at 7 m3

Full scale testing and data gathering

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0

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6 8 10 12 14 16 18 20

Effl

ue

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TSS

(mg

/L)

Settler upflow velocity (m/h)

Biothane Pilot plant 2011TSS Effluent vs Vl settler

TSS Effluent

Study of operational data Biobed++ referenc Pilot plant results paper wastewater

Effect of liquid velocity in Advanced settler on effluent SS

• Up to 19 m/h no effect designing at higher upflow velocities

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Study of operational data Biobed++ referenc

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Testing results paper wastewater

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6/6/11 6/26/11 7/16/11 8/5/11 8/25/11 9/14/11 10/4/11 10/24/11

VLR

(kg

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³/d

)

Biothane Pilot Plant 2011Volumetric loading rate

Pilot plant

Full scale Biobed

Full scale UASB

Pilot: 12.8 kg SCOD/m3.d

BB: 8.9 kg SCOD/m3 .d

UASB:4.28 kg SCOD/m3 .d

Biobed® Advanced pilot 140% loading as compared to EGSB full scale Biobed® Advanced pilot 300% loading as compared to UASB full scale

Advanced Pilot

EGSB full scale

UASB full scale

Biobed® Advanced; smaller settler and reactor

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Smaller settler height • 1.0 meter lower

• Same net volume loading rate

• Higher gross volumetric loading rate

Higher applicable liquid upflow velocity • Smaller required settler area

Reduced settler price

Substantial influence on Capex and Opex • Lower energy demand

1.0 m

net reactor volume

Biobed® Advanced; Easy effluent pipes

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Novel effluent pipes replacing conventional gutters

Less critical in levelling • Reduces short circuiting risk

Less maintenance

Biobed® Advanced; flexible reactor height

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Wastewater characteristics (process) determines reactor height

Complex: Biobed® Advanced UASB up to 6 ~ 10 meters height

Simple: Biobed® Advanced EGSB 10 ~ 20 meters height

Both either in steel or concrete reactors; round or square

Biobed® Advanced; Optimizing investment and operating costs

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Compact settler result in more flexible reactor design

Optimal size: Diameter = 0.8 x Height

Tall is more costly and requires more energy

Biobed® Advanced; Reduced operation costs

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Novel superior settler • Excellent biomass inventory

• Stable growth of granular biomass

Therefore • High COD removal efficiency (long SRT)

• Less chemical consumption; pH, nutrients, anti-foam

• Less operator attention

Overall lower operating costs • Smaller aerobic post treatment

• Less overall maintenance cost

Confirmed by numerous full scale results

Novel Biobed® SMART control system • Will further improve stability and performance

Biobed® Advanced; Resume of advantages

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Improved performance • Based on fundamental research

• Improved superior COD removal efficiencies

• Excellent biomass inventory

• No odour emission

Tailor made design • Flexible reactor height

• Flexible in construction; round steel or square concrete

• Easy effluent pipes

Reduced Capex and Opex • Small compact settler and small reactor

• Low chemical consumption

• Reduced aerobic post treatment

• Small foot print

A proven track record

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Proven Innovation • 25 full-scale Biobed® Advanced plants

• 5 years of full-scale industrial operation

• 2 pilot plant testing locations

• Overall track record of 530 plants

Implemented in • Pulp & Paper

• Chemicals and PTA

• Food: Dairy, Sugar, Potato, Soya

• Brewery & Distillery

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Nov-07 Jun-08 Dec-08 Jul-09 Jan-10 Aug-10 Feb-11 Sep-11 Apr-12 Oct-12

CO

D r

ed

uct

ion

(%)

Date

COD reduction89%

80%

78%

Design

91%

Biobed® Advanced full scale; chemical case

Very high COD removal efficiency for PTA wastewater

Steady biomass increase observed

Biobed® SMART Sludge Management and

Reactor control Techniques

3.

Biobed®SMART reactor control system (1)

Sludge Management and Reactor Control Techniques

Objectives : • Achieve more stable reactor operation

• Achieve higher COD removal efficiency

• Reduce operating costs

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“Real time video from inside the anaerobic reactor”

Development of Biobed® SMART

SMART control box 1. SMART process indicators (early warning)

Online continuous insight for operator in process performance

Based on a combination of different online measurements

Red / green lights to indicate process performance

2. SMART process control loop

Stable process load (dynamic control)

Optimized nutrient dosing

pH optimization

Temperature optimization

3. SMART imaging

Online view on biomass granules in reactor

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Biobed® SMART Process Indicators

Relation between VFA and CH4 in biogas

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Biobed® SMART Process Indicators

Capacity indicator defines if spare capacity is left in the plant (in situ biomass activity test) • Based on patented measuring principle

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Biogas vs Feed flow

Calculated Load Biogas

Biobed® SMART control loop

Pilot plant results with and without Dynamic Control

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Fluctations in gas production in standard operations

Normalized gas production

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Fluctations in gas production SMART Load control

Normalized gas production

Load

Variation + 40%

Variation + 25%

Dynamic Control: Client Case-study

Fruit juice factory in the Netherlands • Flow 600 m3/day

• Load 1.5 ~ 2.0 tons of COD / day

200 m3 Equalisation tank

200 m3 storage tank

3 x 50 m3 Biobed® Modular Plant

High fluctuations in load, flow and low nutrient content

Resulted in poor performance and high costs

From: * Warmenhoven, J.W. and Spanjers, H. (2011). “TOC based control of anaerobic

reactor treating wastewater from a fruit juice packaging factory.” Water Practice & Technology 6 (2)

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Dynamic Control: Client Case-study

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Net Biomass growth

Reduction in N-consumption despite of increased average load

Stable operation reduced operator and analysis cost

+ 11% -40% +32% -56% -43%

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Biobed® SMART in situ real-time imaging

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Biobed® SMART; Advantages

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Lower Capex • Smaller required reactor volume; handling more load

• Less hydraulic buffer volume

• Reducing Carbon Footprint

Reduced Opex • Lower post treatment cost; slightly more biogas

• Lower chemical costs; pH and Nutrients

• Better sludge inventory

• Less maintenance/operator costs

Quality improvement • Better effluent quality

• Early warning system for possible reactor upset

• Improve reliability and availability

• Reduced start-up time

Memthane® The preferred solution for high-strength wastewaters

resulting in crystal clear effluents

4.

Drivers for Anaerobic MBR (1)

Specific wastewater characteristics

FOG (Fat, Oil & Grease) and LCFA (Long Chain Fatty Acids)

• Hamper granulation in UASB or EGSB

High concentrations (COD + salts); e.g. Whey & Thin Stillage

• Un-diluted: no granulation in UASB due to high HRT, salts

• Diluted: too large UASB reactor volume

• Solution often low loaded CSTR systems

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Drivers for Anaerobic MBR (2)

Higher loading rate in CSTR digester achieved by

• Uncoupling of HRT and SRT by use of membranes

Higher COD removal efficiencies & clear effluents

• Smaller post treatment; more compact & less energy consumption

• Higher digestion efficiency, more biogas

• Effluent free of suspended solids; easy nutrient recovery

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Memthane® step-by-ste

Conditioning of high- strength wastewaters.

Influent is fed to the anaerobic bioreactor where the organic components are converted into energy-rich biogas.

Cleaning In Place (CIP)

After anaerobic treatment, the UF membrane unit separates the clean permeate from the biomass.

If required, several polishing techniques are available to further treat the suspended solids free effluent for reuse or recovery of nutrients, while the low COD permeate is often clean enough for direct discharge to sewer.

Biomass is returned to the bioreactor, while a small amount of biomass is removed from the system and discharged after dewatering.

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Memthane®; Features

Treat high-strength effluent previously considered untreatable • High concentrated streams : COD 15,000 – 250,000 ppm

• Superb effluent quality

• Create product for nutrient recovery (N+P)

Maximize renewable green energy production • Generates biogas from wastewater

• Minimizes carbon footprint and water footprint

Remove COD efficiency: > 98% • Avoids costly aerobic post treatment

• Generates more biogas

Reduced OPEX • Reduces disposal costs while generating biogas

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Impact of membranes on anaerobic process

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Anaerobic MBR; full scale case Dairy wastewater

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9 tCOD/day

COD loading and COD removal over 2.5 years 3 day moving average

Memthane®; Track record

Proven Innovation 9 full-scale Memthane® plants

• 4 years of full-scale industrial operation

• 14 pilot plant tests

Implemented in: • Dairy industries

• Bio-ethanol plant; thin stillage

• Cellulosic Bio-ethanol; condensate

• Biodiesel plant

• Food processing

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Ethanol distillery; Case study

Production Capacity: 10,000 m3 Ethanol per year

Bases: Corn

Flow: 700 m3/day / COD: 48 ton/day

TKN: 720 ppm / t-P: 820 ppm

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Biogas Boiler

DAF

Stillage Centrate

BT

Dilution Effluent

DAF Float

BIOBED

Post Treatment

Post Treatment

Biogas

BT

AnMBR sludge stream

MEMTHANE

Ethanol distillery- Case study

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Biogas

Memthane®

Water Re-Use

Evaporator

Thin Stillage

Electricity CHP

Back set water

N - removal Ammonia Stripping

P- removal Struvite & Anitamox

Memthane Development Works…

Water Re-Use RO Treatment

Boiler Feed Water Cooling Water & Other

Ammonia for Re-use

Fertilizer

Decanter

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Full scale design Bio-ethanol

Memthane® treating thin stillage of 45 ton COD/d

COD removal efficiency > 98 - 99% • Gross caloric value >5.4 MW

Electrical balance • Production 2.2 MWe

• Consumption Memthane® 0.3 MWe

Post treatment options • Struvite precipation

• Water Re-use

• Ammonia re-use

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Observations and Conclusions

Biobed® Advanced reactor • Reduced investment and operating costs

• Stable and reliable operation

• 25 full scales

Biobed® SMART • Substantial reduction in operating costs

• More stable operation

• Especially as retrofit to existing plants

Memthane® AnMBR • Cost effective solution for concentrated wastewaters

• Crystal clear effluents

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Biothane: Establishing growth through innovation Thanks for your attention For further information or questions Please contact: Jan Pereboom; Marketing Manager at Biothane jan.pereboom@veoliawater.com or visit our booth: Hall 5 F124

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