13-2-2013

Anaerobic effluent treatment in the pulp and paper industry

www.paques.nl

2

Who is Paques?

• Family owned business

• Founded in 1960

• Number of employees : ~400

• Operations in The Netherlands, China, Brazil, and sales office in Canada

• Worldwide presence through network of partners, partnering strategy

• Innovative biological applications for wastewater and gas

• 2011: SKion GmbH, the investment firm of German entrepreneur Susanne Klatten (BMW, ALTANA, SGL) purchases 20% shares

• 2011: JV with Shell for biological gas desulphurization

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• Paques has around 1500 references worldwide

– Mainly anaerobic water treatment (energy from wastewater) and biogas desulphurization

– Market leader in pulp & paper, beer & beverage and food sector

– Strong portfolio in sulphur based biotechnology

• Growing and developing in:

– Metal and Mining

– Oil and Gas through Paqell

– Petrochemical

– Algeae

– Biobased chemicals

Who is Paques?

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• Meet safe water discharge requirements

• Reduce water consumption (water footprint)

• Produce green gas (carbon footprint)

• Upgrade biogas

• Resource recovery from used water

By offering:

• Biological processes and engineering packages

• Integrated solutions • Reliable

• High uptime

• Energy efficient

• Best performance with attractive economics

Paques helps companies to:

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• Process design

• Basic and detailed engineering

• Manufacturing

• Contracting

• Construction

• Research & Development

• Laboratory services

• Pilot testing

• Consultancy and services

Paques’ services

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More than 1,500 reference plants in more

than 60 countries in the following industries:

• Pulp and Paper

• Beer and Beverages

• Food

• Distilleries

• Chemical industry

• Metal and Mining

• Oil and Gas

• Municipalities

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Anaerobic Waste Water Treatment

Pulp & Paper

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Purpose

• Removal of organic contaminants

• Biogas production

Paques

• The word leader in anaerobic treatment

• More than 875 references in more than 60 countries

Anaerobic COD removal

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Smurfit Kappa Roermond Papier 1983

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100st IC reactor in P&P

started up in 2008

DS Smith France

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Sludge granulation is the most popular anaerobic technology to treat pulp & paper effluent

UASB/IC

75%

AF

2%CSTR

7%

FB

2%

EGSB

14%

13

No.1 in anaerobic treatment of wastewater for pulp & paper industry

PAQUES

59%

A

17%

B

8%

C

6%

D

6%E

4%

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Traditional aerobic process

BOD + O2 H2O + CO2 + BIOMASS

CO2 + H20

45

45

10 100

Aerobic sludge

Effluent

Aerobic biomass (~4 g/l MLSS)

Aerobic sludge

• High growth rate

• High energy requirement

• High sludge production

• Flocculant sludge

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Concerns of Aerobic Treatment

- Important Space needed - Energy Requirement for Aeration - Important Sludge Production - Sensitive to Loading Variation - Problems of Sludge Separation

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Anaerobic process

COD CH4 + CO2 + BIOMASS

Anaerobic methanogenic biomass

• Low growth rate

• Production of reusable methane (green

energy)

• Low sludge production (& biomass is

asset rather than waste)

• Granular biomass

Anaerobic biomass

CO2 + H20

45

45

10

Effluent 100

Aerobic sludge

CH4 + CO2

75

20

100

5

Effluent

Anaerobic sludge

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Why anaerobic pre-treatment ?

- reduced energy consumption

- reduced sludge production

- more stable operation

- energy production

- reduced green house effect

In aerobic

plant

Revenue

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Secondary Clarifier before anaerobic system installed

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Secondary Clarifier after anaerobic system installed

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Improvement of aerobic sludge

Before anaerobic

system installed

After anaerobic

system installed

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Lab testing: Oxitop

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Pilot testing

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• High rate (20-30 kg COD/m3/d)

• Small footprint

• Low hydraulic retention time

• Self regulating system

• Intensely mixed biomass at bottom reactor

• Optimal sludge retention at top reactor

BIOPAQ®IC reactor

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Advantages BIOPAQ® IC reactor

• Proven technology, > 875 BIOPAQ references

• Closed system, corrosion free materials

• Minimal foot-print (space saving and odor emission

surface limited)

• Completely mixed reactor compartment due to Internal

Circulation principle

• Optimal sludge retention due to two-staged separation

• Maximal recovery of biological alkalinity, reduced

chemical costs

• Robust & more stable due to

- two-staged concept

- automatic internal dilution (IC)

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Feasibility of anaerobic effluent treatment MILL PROCESS FEASIBILITY OF ANAEROBIC

TREATMENT

Mechanical Pulping

Debarking

RMP, Ground wood

TMP, BTMP (Peroxide)

CTMP, BCTMP (Peroxide)

APMP (Peroxide)

-

+

++

+/++

++

Semi Chemical Pulping

NSSC

Soda pulping

+

+

Chemical Pulping

Sulfite pulp condensate

Sulfite bleaching: E,O,P

Sulfite bleaching: C,H,D

++

+

-

Kraft pulp condensate

Kraft bleaching: E,O,P

Kraft bleaching: C,H,D

++

+

-

Dissolving pulp condensate

Bleaching: E,O,P

Bleaching: C,H,D

+

+

-

Secondary Fibres

Wastepaper, DIP ++

Non-wood (soda) Pulping

Straw, Bagasse, Cotton Linters

+

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Raw material and COD removal

Raw material COD efficiency %

OCC 75 – 85

MWP 65 - 75

MOW 60 - 70

ONP 50 - 55

Mech. pulp / spruce 50 - 55

Mech. pulp / aspen 65 - 75

Condensates 75 - 95

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General flow diagram

Sludge

dewatering

N,P

Effluent

Primary clarifier Aeration tanks

Sec. clarifier

sieve

Influent

Return sludge

Biogas

Gasholder Flare

IC reactor Conditioning

tank

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Zero discharge concept at paper mill

Conditioning tank IC Reactor

Aereation

Water storage tank

Secondary clarifier

Aereation basins

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SCA Newhythe - UK

IC diameter 9.5 m

Height 20 m

Volume 1,400 m3

Flow 6,000 m3/d

COD 5,000 mg/l

COD 30 tpd

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COD-load (kg/d)

IC Reactor COD load

0

5000

10000

15000

20000

25000

30000

35000

40000

45000

1-1

-2004

15-1

-2004

29-1

-2004

12-2

-2004

26-2

-2004

11-3

-2004

25-3

-2004

8-4

-2004

22-4

-2004

6-5

-2004

20-5

-2004

3-6

-2004

17-6

-2004

1-7

-2004

15-7

-2004

29-7

-2004

12-8

-2004

26-8

-2004

9-9

-2004

23-9

-2004

7-1

0-2

004

21-1

0-2

004

4-1

1-2

004

18-1

1-2

004

2-1

2-2

004

16-1

2-2

004

30-1

2-2

004

kg

CO

D/d

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Final effluent COD (mg/l)

Final Effluent COD

0

20

40

60

80

100

120

140

160

180

200

1-1

-2004

15-1

-2004

29-1

-2004

12-2

-2004

26-2

-2004

11-3

-2004

25-3

-2004

8-4

-2004

22-4

-2004

6-5

-2004

20-5

-2004

3-6

-2004

17-6

-2004

1-7

-2004

15-7

-2004

29-7

-2004

12-8

-2004

26-8

-2004

9-9

-2004

23-9

-2004

7-1

0-2

004

21-1

0-2

004

4-1

1-2

004

18-1

1-2

004

2-1

2-2

004

16-1

2-2

004

30-1

2-2

004

CO

D (

mg

/l)

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COD removal (%)

IC Reactor COD removal efficiency (%)

0,0

10,0

20,0

30,0

40,0

50,0

60,0

70,0

80,0

90,0

100,0

1-1

-2004

15-1

-2004

29-1

-2004

12-2

-2004

26-2

-2004

11-3

-2004

25-3

-2004

8-4

-2004

22-4

-2004

6-5

-2004

20-5

-2004

3-6

-2004

17-6

-2004

1-7

-2004

15-7

-2004

29-7

-2004

12-8

-2004

26-8

-2004

9-9

-2004

23-9

-2004

7-1

0-2

004

21-1

0-2

004

4-1

1-2

004

18-1

1-2

004

2-1

2-2

004

16-1

2-2

004

30-1

2-2

004

Eff

icie

ncy (

%)

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SAICA 3, Spain

Diameter 9.5 m Height 24 m Volume 1,680 m3

Flow 8,000 m3/d COD 5,800 mg/l COD 47 tpd

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SAICA 3: Biogas production and VLR

15.000

15.500

16.000

16.500

17.000

17.500

18.000

18.500

JAN FEB MAR APR MAY JUN JUL AUG

Bio

gas p

rod

ucti

on

in

m3/h

22

23

24

25

26

27

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29

30

VL

R i

n k

g C

OD

/ m

3.d

Biogas production Nm3/h VLR in kg COD / m3.d

Loading rate and biogas

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VLR vs COD Efficiency

0

10

20

30

40

50

60

70

80

90

100

0,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 45,0

VLR kg/m3/d

CO

D e

ffic

ien

cy

Performance at high loading

Volumetric Loading Rate (VLR) in kg COD/m3.d Loading rate versus biogas

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Palm Wörth, Germany

Diameter 9.5 m Height 24 m Volume 2 x 1,680 m3

Flow 9,000 m3/d COD 5,500 mg/l COD 50 tpd

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Papierfabrik Palm, Germany TL, CM

BIOPAQ®IC

2 x 1680 m³, Gasbuffer 500 m³, Gasflare 1200 m³/h

THIOPAQ®60/1.2

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Ruhrverband, Germany Tissue

BIOPAQ®IC

2 x 195 m³

THIOPAQ®ECO

2004

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Emin-Leydier, France Diameter 9.5 m Height 24 m Volume 1,680 m3

Flow 6,500 m3/d COD 5,500 mg/l COD 36 tpd

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Cartonneries de Gondardennes France TL, CM

Turn-key wwtp

Anaerbic + aerobic

BIOPAQ®IC 1190 m³

Gasbuffer 30 m³

Gasflare 900 m³/h

2006

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Rock-Tenn Solvay Paperboard, USA

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Smurfit Kappa, UK

IC 6 x 24 m Flow 3000 m3/d COD 6000 mg/l

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Stora Enso, Germany

Hagen Kabel (LWC from spruce)

Diameter 2 x 8 m Flow 24,000 m3/d

Height 20 m COD 1,200 mg/l

Volume 2 x 1,000 m3 COD 30 ton/d

Eilenburg (DIP, Newsprint)

Diameter 4 x 5 m Flow 15,000 m3/d

Height 16 m COD 1,500 mg/l

Volume 4 x 310 m3 COD 22 ton/d

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Mechanical Pulping Process: TMP by Sound Raw materials: Masson Pine Production: 200tpd WWTP biological start up in 2001

Nanping Paper, China

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Mechanical Pulping Process: PRC-APMP by Andritz Raw materials: Aspen Production: 500tpd WWTP biological start up in 2002

Yueyang Paper, China

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UPM Kymmene, Germany SC/LWC

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Fujian Nanping Paper, China TMP/DIP

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YueYang Paper, China

Mechanical Pulping: Aspen/Eucalyptus

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Chen Loong, China

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M-Real, Austria Sulphite Condensate