Upgrade & Expansion of Existing ETPs at Pulp & Paper Mills Marc Krieger IPPTA Conference – Kashipur 10-11 December, 2015 Director of Business Development

Upgrade & Expansion of Existing ETPs at Pulp & Paper Mills

Marc Krieger

IPPTA Conference – Kashipur 10-11 December, 2015

Director of Business Development – Asia-Pacific

Proprietary and confidential

• Increase of ETP capacity as a result of expansion of production activity in the mill

Increased production capacity

Additional production lines

• Improve effluent quality : Reduce BOD, COD

Nitrification / de-nitrification (NH4, TN)

Color reduction

ZLD implementation

Problem Definition – When is ETP Upgrade / Expansion Required


Main Challenges in ETP Upgrade / Expansion

• Technology upgrade to ensure meeting stricter compliance requirements

• Maximum utilization of existing infrastructure and ETP components : aeration tanks, clarifiers, air blowers, etc.

• Minimize the need for additional land allocation and civil works

• Minimize CAPEX

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Proprietary and Confidential

Traditional Solutions for Effluent Treatment - General

Low O&M cost Simple to operate

Low effluent quality Operation problems

(odors) Long SRT 20 - 30

days = large area

Extensive

• Oxidation ponds • Attached Growth • Suspended Growth

Simple to operate Resistant to shock loads (flow, toxicity) Small footprint

Lower effluent quality Simple process control Operational problems

(odors, clogging)

Good treatment

More space required Complex operation /

process control Less resistant to

shocks (load, toxicity)

Intensive


• MBBR – Moving Bed Bi-Reactor

• Provides the process advantages of fixed film while eliminating the disadvantages, and enables achieving superior effluent quality

• Proven technology in the pulp & paper sector

• Increase of ETP capacity - in the range of 30 - 80% - when converting ASP to MBBR, or implementing MBBR before existing ASP

Advantages of Biomass Carrier Technologies - MBBR


Advantages of Biomass Carrier Technologies - MBBR

• Maximum design flexibility in upgrade / expansion of existing ETPs

• Maximum utilization of existing tanks = minimum requirement for additional footprint and civil works

• Simple & fast implementation : in most cases ETP operates throughout the upgrade works

• Staged investment : in “real time”, parallel to actual increase in mill capacity


Recycled, high-density polyethylene

Highly openexternal design

>650 m2/m3

Effective surface area

Optimal oxygen andnutrients transfer

Applicable for various biological processes

Aqwise Biomass Carriers protect biofilm against abrasion, ensures mass transfer efficiency and prevent clogging

Innovation That Works


High effective surface area for biofilm growth : 650 m2/m3

Openings in outer circumference create turbulent flow within the carrier, and minimize distance to biofilm from to 0 - 3 mm across the entire media

10 year guarantee for mechanical integrity of the carrier, MoC : HDPE

Same media for all process stages

Aqwise Biomass Carriers – Advantages to Remember


High load Medium load

Aqwise Biomass Carriers - ABC

Low load

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RA

SSludge

Treatment

Problem

Need to expand existing ASP to treat higher flow / load

SolutionMBBR upstream of the ASP to achieve COD &BOD reduction

MBBR + ASP Configuration – Increasing ETP Capacity

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RA

S

SludgeTreatment

IFAS Configuration –Improving Effluent Quality

Problem Need to upgrade existing ASP to achieve Nitrogen removal

Solution Simultaneous BOD and Nitrogen removal

Internal Recirculation

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Oxidation pondOxidation pond

MBBR Configuration – Effluent Polishing

ReservoirReservoir

BOD Polishing and Nitrification

Problem

Need to upgrade ETP to achieve improved effluent quality (BOD & Ammonia)

Solution

Addition of MBBR unit for BOD polishing and nitrification

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REQUIREMENTS

SOLUTION

HIGHLIGHTS•Customer:

•Location:

•Capacity:


Case Study: Pulp & Paper

Paper Factory, Italy

Europaper

Italy

2,000 m3/d

• Addition of production lines led to increase of wastewater capacity and BOD loads

• AGAR® MBBR installed upfront of existing effluent treatment plant (RBC + clarifier)

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Europaper – Italy, 2005Europaper – Italy, 2005

MBBR before existing WWTPMBBR before existing WWTP

2,000 m2,000 m33/d/d

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CASE STUDY – Valdivia CMPCChile, 2006DAF-MBBR Configuration (8,500 m3/d)

Client: Large pulp and paper factory in Chile

Production: Thermo Mechanical Pulping; paper board

Wastewater flow: 8,500 m3/dChallenges: Upgrade an existing plant – flow increase from 4,500 to 8,500 m3/d, within limited footprintEffluent requirement: Discharge to river Design: DAF – MBBR - DAF

Results: Successful upgrade with low HRT

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CASE STUDY – Valdivia CMPCChile, 2006DAF - MBBR Configuration (8,500 m3/d)

HRT = 2 h

Parameter Value

BOD in [mg/l] 680

BOD out [mg/l] required 300

BOD out [mg/l] actual 260

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CASE STUDY – Valdivia CMPCChile, 2006DAF - MBBR Configuration (8,500 m3/d)


• Color – typically in pulp mills Originates from lignins in natural raw materials (wood

chips), or from dyes (colored tissue paper) Not completely bio-degradable – residual color after

the biological stage Requires additional physico-chemical treatment stage

after the biological reactor : clari-flocculator, DAF

• Hardness Originating from calcium-based chemicals used in the

paper making process Potential for precipitation on the carriers – scaling. Will

impact carrier weight / mixing

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What Everyone Wants to Know – How Much Does it Cost ???

And, of course, there is no “simple” answer.

Will be determined case by case based on : Effluent characteristics : flow & quality

Effluent quality requirements : discharge to environment, ZLD, irrigation

Existing ETP infrastructure : technology, age, level of operation & maintenance

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Contact Information

[email protected]

Marc KriegerDirector of Business Development – Asia-Pacific

Websitewww.aqwise.com

Telephone+91 85275 99099

Company Highlights


About Aqwise

Aqwise is an industry leader in advanced bio-film based water and wastewater treatment technologies

Expertise– Strong biological process know-how– Multi-disciplinary expert staff

Global Reach, Local Presence– Over 350 installations in 40 countries– World-wide regional offices, sales

representatives and partners


Global Solution ProviderAqwise is a trusted solution provider for municipal and industrial customers

> 180 Municipal

Installations

> 40 Countries

Worldwide

> 170 Industrial

Deployments

Proven Track Record of Success

Over 350 installations worldwideMunicipal:

New plantsUpgradeExpansion

Industrial: Food & BeveragePulp & PaperPharmaceuticalOil & Gas

Over 350 diverse installations worldwide

Proven Track Record of Success


Strong Customer BaseAqwise technology solutions are used by many global brands and industry leaders


Research & DevelopmentAqwise is actively involved in the development of new and innovative biological solutions

Field Test Facilities

Research Facilities– Advanced Research & Development center

located in Israel– Biological process excellence center

Wastewater Treatment– Development of new biological processes for

treatment and compliance to new standards

Drinking Water– Focus on efficient treatment of various pollutants

Aqwise Laboratories


Customer Benefits/

DURABLE & STABLEHighly resistant to hydraulic shock loads with short recovery time after toxic loads

LOW MAINTENANCESimple process controlLow maintenance & operational costs

ECO FRIENDLYCarriers manufactured from recycled HDPE, minimal land usage, reduced sludge generation

SMALL FOOTPRINTSuitable for both new applications and existing plant upgrades

COST EFFICIENTRequires minimal civil works, short project life cycle and low CAPEX/OPEX

SCALABLE & FLEXIBLESmooth upgrade or gradual expansionbased on just-in-time investment


Business ModelsAqwise offers a wide range of business models to fit customer needs

Process PackageProcess and detailed engineering design services, carrier and equipment supply

Turn-Key ProjectFull project management and implementation

Professional ServicesOn-site pilot demonstration, process start-up and supervision, full after-sales support

FinancingTailor-made financial models to meet customer budget requirements

Package Plant Compact containerized and pre-fabricated solutions

Aqwise in India


Activity in India to Date

First projects in public sector, with Indian EPC company : STP 30 MLD, WTP 160 MLD (Agra)

Permanent presence in India since May 2014, based in Delhi

Focus on industrial / private sector : ETP upgrades & expansions

Projects to date : ETP expansion for Teva API MBBR technology demonstration – Hindustan Unilever Advanced stages of negotiations with clients in pulp &

paper, food & beverage, pharma & chemical sectors


Case Study: Pharma - API

Upgrade and expansion of an existing ETP (Effluent Treatment Plant) at an API facility in India

Conversion of activated sludge process to 3-stage MBBR in existing reactor

Addition of DAF after existing clarifier to improve effluent quality : pre-treatment to UF/RO for ZLD

Aqwise scope of supply : Supply of MBBR media and screens, DAF unit All process and detailed design Project management and site supervision of local contractor

Completed Q3 2015

REQUIREMENTS

SOLUTION

HIGHLIGHTS• Customer:

• Location:

• Capacity:


Case Study: Surface Water Treatment

Drinking Water Treatment Plant - Agra, India

Triveni Engineering & Industries

Yamuna River - Agra, India

163,000 m3/d (MBBR)

• Modernization of existing drinking waterplant, serving population of 2 million people

• Cost-efficient surface water treatment• AGAR® MBBR and UF membrane polishing• Efficient COD reduction and BNR• Adaptive to variable loads• Minimized chlorine dosing

Documents

Upgrade & Expansion of Existing ETPs at Pulp & Paper Mills Marc Krieger IPPTA Conference – Kashipur 10-11 December, 2015 Director of Business Development