THERMO-SYSTEM The No. 1 in Solar Drying Systems
THERMO-SYSTEM today Partners & Licensees USA, Austria, France, Spain Refereces >150 000 m² of Solar and Solar-Assisted Drying Plants in 15 Countries
Drying of Sewage Sludge Background and Perspectives Thermo-System Industrie- & Trocknungstechnik GmbH 2007
Annual amount of sewage sludge per 1 000 persons 600 500 400-600 t Sludge mass [t] 400 300 200 100 0 3-5 % Mechanically dewatered 80 t 24 t 25 % 75 % Water Dry sludge Dry solids 20 t 90 % Dry solids concentration [%]
Options of Sludge Disposal o o o Sea disposal Landfill Agriculture (increasing restrictions) o o Land Restoration & Landscaping Incineration Sludge Disposal [1.000 t DS] 300 250 200 150 100 50 0 State of Baden-Württemberg 1995-2005 Landfill Agriculture Incineration Land Restoration
Sludge Drying & Agriculture + Land Restoration oeasy interim storage and handling o Low transport and distribution costs o No odor problems and emissions (acceptance) oless washing out of nutrients or negative impacts on vegetation o Reduction of pathogens and total volatiles (class A or B) o All other ways of disposal open
Sludge Drying & Incineration o o Reduction of costs for transport & incineration Increase of heating value Dewatered Solar Dried kg 1000 750 500 Mass of Sludge Water reduction Mass of Sludge o Mono-, Co- and Decentalized Combustion 20 30 40 50 60 70 80 Dry Solids 0 90 % o Reduction of CO 2 -Emissions o Cost stabilization
Example: Reduction of traffic & transport costs (50 000 IE) Evaporation: ~ 3.000 t/a 4.000t/a@20%DS 200 trucks Solar Drying Plant 1.000t/a@60 90%DS 50 trucks
20-30 kwh/t Water Energy requirement in kwh / tons evap. Water 100% Solar energy free! solar elektrisch Solar Drying Source: LFU/LFW Bericht Füssen 90-12 1 0 15 kwh/t Water Conventional Drying ~100 l Oil/t Water therm. Energy el. Enegy 885 Source: Univ. Hohenheim
Sludge Input Solar Dryer 1.600 t @ 22 % DS Decentralized Sludge Drying & Reformation Output Solar Dryer = Input Reformer 500 t @ 70 % DS Output Reformer 150 t of Ash
Solar Drying of Sewage Sludge: Technology Thermo-System Industrie- & Trocknungstechnik GmbH 2007
THERMO-SYSTEM Solar Sludge Drying solar radiation backup-heating systems (optional) controlled air inlet controlled aeration rate controlled air exchange rate mixing, turning, aeration fully automatic control
THERMO-SYSTEM Covering Polycarbonate Double Skin Sheets Glass PE-Air-Bubble-Foil PE-Double-Foil (inflated)
THERMO-SYSTEM Aeration Systems Stationary MoviVent I MoviVent II
THERMO-SYSTEM Backup Heating Systems Hot Water Air Heaters High Performance Floor Heating Exhaust Gas Heater
THERMO-SYSTEM Exhaust Air Control Free Convection Controlled Air Removal Air Treatment (optional) Biofilters
Solar Sludge Drying with the Electric Mole
Loading of a chamber: Continuous or at once
Electric Mole : Unloading by a front end loader Beispiel: Input 3 500 t TR 25 /a; Output 970 t TR 90 /a = 40 LKW Trocknungszone: 25 75 t TR 25 / Zyklus
Maintenance & Operation Comparison
THERMO-SYSTEM SludgeManager
SludgeManager : Fully mechanized from point to point
SludgeManager : Sludge and more.
REFERENCES
Ellwangen: 40 000 IE Total sludge production: 2 000 t/a (25-30 % DS) -> 700 t/a (70 % DS)
Füssen: 70 000 IE top view side view (cut) 4 drying chambers, 10 x 50 m
Füssen: 70 000 IE until 1998 2 500 t / a Land Reconstruction 100 Trucks pa, 25 t/load Eastern Germany 25-30 % DS 2500 t x 46 /t = 115 000 /a
Füssen: 70 000 IE 2 500 t/a 25-30 % DS until 1998 100 Trucks pa, 25 t/load Land Reconstruction Eastern Germany 2500 t x 46 /t = 115 000 /a 2500 t x 89 /t = 222 500 /a Incineration Coal Power Plant
Füssen: 70 000 IE 2 500 2 500 t / t/a Jahr 25 25-30 - 30 % DS TR until 1998 100 Trucks pa, 25 t/load Land Reconstruction Eastern Germany 2500 t x 46 /t = 115 000 /a since 2000 Solare Solar Trocknung Drying 2500 t x 89 /t = 222 500 /a Incineration Coal Power Plant 35 Trucks pa 70 % DS TR 890 t x 89 /t = 79 000 /a -> Savings: 40 000 km of Transport Distance pa 143 000 of Disposal Costs pa +carbon debits +energy produced in power plant
Krems: 180 000 IE
Bad Vöslau 300 000 IE 14 000 t/a ~ 5 000 t/a 4 100 t 4 100 t 4 000 t 4 000 t Top Aufsicht view Feuerung Firing Fernwärmenetz Long distant heating Side Längsschnitt view (cut)
CASE STUDY PRESENTATION
Solar Drying of Sewage Sludge Palma de Mallorca Purpose and Target Agricultural utilization of sewage sludge is massively decreasing due to political volition and low acceptance in the population. Because of the island position of Mallorca, sludge disposal on the Spanish mainland comes with high transportation cost. The touristic character of the island dictated an environment-friendly and flexible concept. Thanks to the climatic conditions of the island, solar drying of the sludge was the best solution. To avoid traffic and transportation cost, the dried sludge is incinerated in the neighboring heat and energy providing waste incineration plant.
Palma de Mallorca World s Largest Solar Drying Plant for Sewage Sludge
Demands on the Drying Plant Generally investment as well as operation cost should be reduced to a minimum. The plant technology should be preferably robust and low in maintenance effort. Moreover, neither special knowledge nor skills should be required from the operational staff. Besides the usage of free solar energy, the option of adding waste heat from a CHPS of the waste water treatment plant should be feasible reducing he solar surface demand and/or increase on the performance during winter time. The Thermo-System SolarBatchsystem was the winner against the competition of conventional drying as well as other solar drying systems.
Operation and Function Dewatered sludge is delivered by trucks to a covered reception and handling hall. It is carried to one of the twelve drying halls by wheel loader. Since the drying plant in Palma is a regional facility the sludge is transported by truck from the various WWTPs to the drying facility. On each work day, a front end loader unloads one of the 12 drying chambers of dried sludge. Then it is immediately reloaded with 80-150 metric tones of wet sludge. Loading and unloading is fast, taking less than 3 hrs in total. Also the time requirement for supervision and maintenance is low and takes typically no more than one or two hrs per day for the whole facility. After filling the hall and spreading the sludge roughly on the drying area, the fullyautomated drying process is started. The required thermal energy that is needed for drying, mainly comes from free solar radiation, whereas three drying halls are assisted with residual waste heat of the sewage gas CHPS of the waste water treatment plant.
Technical Data WWTP Capacity: 600 000 PE Wet Sludge Quantity: 30 000 t/year with 20-30% DS Stabilization: various Drying Target DS Content: 60-80%, throughout the year Dried Sludge Quantity: approx. 10 000 t/year Plant Data Total Footprint: approx. 20 000 m² Covering Material: Safety Glass (4mm) / Insulating Glass (16mm) Waste Heat: 0-500 kw Workload Filling by wheel loader Fully automated drying Clearing by wheel loader with direct loading of the dried sludge on trucks Environment Reduced transport volume Incineration with gain of energy Prevention of CO 2 emissions
Solar Drying of Sewage Sludge HERSONISSOS, CRETA PARAMETER OF OPERATION unit TOTAL QUANTITY OF INLET SLUDGE tn/yr 2000 DS in. % 22 DS out % 70 HEIGHT OF SLUDGE cm 10 TOTAL DRIED SLUDGE tn/yr 629 EVAPORATED WATER tn/yr 1372 CYCLES PER CHAMBER cycles/yr 24 DRYING TIME days 14
HERSONISSOS, CRETA