CA2768176A1 - Wastewater sludge processing system - Google Patents
Wastewater sludge processing system Download PDFInfo
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- CA2768176A1 CA2768176A1 CA2768176A CA2768176A CA2768176A1 CA 2768176 A1 CA2768176 A1 CA 2768176A1 CA 2768176 A CA2768176 A CA 2768176A CA 2768176 A CA2768176 A CA 2768176A CA 2768176 A1 CA2768176 A1 CA 2768176A1
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- Prior art keywords
- solvent
- oil
- sludge
- solids
- cellulose
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F11/00—Treatment of sludge; Devices therefor
- C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
- C02F11/121—Treatment of sludge; Devices therefor by de-watering, drying or thickening by mechanical de-watering
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F9/00—Multistage treatment of water, waste water or sewage
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D25/00—Filters formed by clamping together several filtering elements or parts of such elements
- B01D25/12—Filter presses, i.e. of the plate or plate and frame type
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F11/00—Treatment of sludge; Devices therefor
- C02F11/18—Treatment of sludge; Devices therefor by thermal conditioning
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L1/00—Liquid carbonaceous fuels
- C10L1/02—Liquid carbonaceous fuels essentially based on components consisting of carbon, hydrogen, and oxygen only
- C10L1/026—Liquid carbonaceous fuels essentially based on components consisting of carbon, hydrogen, and oxygen only for compression ignition
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L3/00—Gaseous fuels; Natural gas; Synthetic natural gas obtained by processes not covered by subclass C10G, C10K; Liquefied petroleum gas
- C10L3/06—Natural gas; Synthetic natural gas obtained by processes not covered by C10G, C10K3/02 or C10K3/04
- C10L3/08—Production of synthetic natural gas
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L5/00—Solid fuels
- C10L5/40—Solid fuels essentially based on materials of non-mineral origin
- C10L5/46—Solid fuels essentially based on materials of non-mineral origin on sewage, house, or town refuse
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/02—Treatment of water, waste water, or sewage by heating
- C02F1/04—Treatment of water, waste water, or sewage by heating by distillation or evaporation
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F11/00—Treatment of sludge; Devices therefor
- C02F11/002—Sludge treatment using liquids immiscible with water
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F11/00—Treatment of sludge; Devices therefor
- C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
- C02F11/13—Treatment of sludge; Devices therefor by de-watering, drying or thickening by heating
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E50/00—Technologies for the production of fuel of non-fossil origin
- Y02E50/10—Biofuels, e.g. bio-diesel
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E50/00—Technologies for the production of fuel of non-fossil origin
- Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel
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- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Life Sciences & Earth Sciences (AREA)
- Hydrology & Water Resources (AREA)
- Environmental & Geological Engineering (AREA)
- Water Supply & Treatment (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Treatment Of Sludge (AREA)
- Heat Treatment Of Water, Waste Water Or Sewage (AREA)
- Solid Fuels And Fuel-Associated Substances (AREA)
Abstract
The Wastewater sludge processing system takes sludge directly from the municipal waste water treatment plant and processes it using a low-temperature, low pressure process that has no waste products. The process dries the sludge and separates it into oil that is turned into biodiesel feedstock, cellulose/minerals that are used for heating the process, and water that is reused in the process.
Description
Wastewater Sludge Processing System GOVERNMENT INTEREST STATEMENT
[P0011 None BACKGROUND OF THE INVENTION
1. Field of Invention 10002] The invention relates generally to a process for the treatment of wastewater sludge into desirable products with no undesirable waste left over.
More specially the. process relates to drying the sludger, and separating the sludge into oil, water, and celluloseirninerals by the use of chemical and physical reactions, 2. Desscription of the Background [0003] Sewage is created by residences, institutions, hospitals and commercial and industrial establishments. Raw influent (sewage) includes household waste liquid from toilets, dati :s, showers, kitchens, sinks, and so forth that is disposed of via sewers. In many areas, sewage also includes liquid waste from industry and commerce. Municipal wastewater therefore includes residential, commercial, and industrial liquid waste discharges, and may include storm water runoff, [0004) Conventional sewage treatment involves three stages, called primary, secondary and tertiary treatment. First, the solids are separated from the wastewater stream, Then dissolved biological matter is progressively converted into a solid mass by using indigenous, water-borne micro-organisms. Finally, the biological solids are neutralized then disposed of or re-used, and the treated water may be disinfected chemically or physically (for example by lagoons and microfÃltration)... The final effluent can be discharged into a stream, ri'''ver, bay, lagoon. or wetland, or it can be used for the irrigation of a golf course, green way or park. if it is sufficiently clean, it can also be used for groundwater recharge or agricultural purposes.
[P0011 None BACKGROUND OF THE INVENTION
1. Field of Invention 10002] The invention relates generally to a process for the treatment of wastewater sludge into desirable products with no undesirable waste left over.
More specially the. process relates to drying the sludger, and separating the sludge into oil, water, and celluloseirninerals by the use of chemical and physical reactions, 2. Desscription of the Background [0003] Sewage is created by residences, institutions, hospitals and commercial and industrial establishments. Raw influent (sewage) includes household waste liquid from toilets, dati :s, showers, kitchens, sinks, and so forth that is disposed of via sewers. In many areas, sewage also includes liquid waste from industry and commerce. Municipal wastewater therefore includes residential, commercial, and industrial liquid waste discharges, and may include storm water runoff, [0004) Conventional sewage treatment involves three stages, called primary, secondary and tertiary treatment. First, the solids are separated from the wastewater stream, Then dissolved biological matter is progressively converted into a solid mass by using indigenous, water-borne micro-organisms. Finally, the biological solids are neutralized then disposed of or re-used, and the treated water may be disinfected chemically or physically (for example by lagoons and microfÃltration)... The final effluent can be discharged into a stream, ri'''ver, bay, lagoon. or wetland, or it can be used for the irrigation of a golf course, green way or park. if it is sufficiently clean, it can also be used for groundwater recharge or agricultural purposes.
[0005] The sludges accumulated in a wastewater treatment process must be treated and disposed of in a safe and effective manner. The purpose of digestion is to reduce the amount of organic matter and the number of disease.causing microorganisms present in the solids. The most common treatment options include anaerobic digestion, aerobic digestion, and composting, 10006] Choice of a wastewater solid treatment method depends on the amount of solids generated and other site-specific conditions. Hovv~ever, in general, composting is most often applied to smaller-scale applications followed by aerobic digestion and then lastly anaerobic digestion for the larger-scale municipal applications.
1000$] It has now been found that wastewater sludge can be processed economically by virtue of using products of the treatment process as a fuel for one or more heating steps in the process. It has further been found that wastewater sludge can be processed such that at the end of the process of the present invention, all. the useful materials-cil, cellulose and minerals-have been captured. Most important, it has still further been found that wastewater sludge can be processed such that there is nothing left to be incinerated, landfilled, or otherwise disposed of, making the system of the present invention a truly zero-waste process.
['009] In accordance with an em odiment of the invention, a zero-waste method of processing wastewater sludge is provide such that at the end of the process of oil, cellulose, and minerals have been captured and there is substantially nothing left to be incinerated. landfilied, or otherwise disposed of.
[00010] in accordance with another embodiment of the invention, a process is provide which comprises the steps of;
a- transferring sod wastewater sludge from a treatment plant to a wet sludge holding bin, said wastewater sludge containing from about 20 to 45%
solids by weight, b- drying said wastewater sludge to about 90% solids, grinding the dried wastewater sludge an transferring the dried ground sludge to a mixer rector, c- within the mixer reactor mixing the dried ground sludge with a solvent and heating to produce viscous suspension of hydà w.. arbons or cellulose and minerals in suspension, d- separating liquids and solids, e- heating the separated liquids to the boiling point of the solvent and the boiling point of the residual water prior and collecting evaporated solvent and residual water, f- transferring solvent-free oil to a holding tank, g- condensing evaporated solvent and residual water and separating water from solvent, and h- transferring separated solvent and residual water to the mixer reactor of step (c), 00011 In accordance with a further embodiment of the invention the step of separating liquids and solids is performed in a filter press, and further comprises the steps of;
i- collecting cellulose-mineral mixture from: said filter press drying said cellulose-mineral mixture and removing and collecting solvent 1<- reusing collected solvent in the process at step (c), and I- transferring dried cellulose/mineral mixture to a furnace and using the heat from the furnace in at least one of steps (b), (c) and ().
100012] In accordance with another embodiment of the invention the oil from step (f) is approximately 60% fatty acids, is approximately 65 weight % 1 and C18, and is substantially free of sulfur, [00013): In accordance with still another embodiment of the invention: the process extracts about 18% oil by weight from undigested sludge and 1'1% oil by weight from digested sludge.
100 014) In accordance with another embodiment of the invention the step of separating liquids and solids produces a filtrate comprising extracted oil, residual solvent, and traces of water, f00015] BRIEF DESCRIPTION THE DRAWINGS
10001) FIG., I is part I of the process flow diagram.
[00017] FIG. 2 is part 2 of the process flow diagram.
[00018] FIG, 3 is part of the process flow diagram.
DETAILED DESCRIPTION
[00019] it is advantageous to define certain terms before describing the invention.
It should be appreciated that the following definitions are used throughout this application.
Definitions [00020] The term "wastewater sludge" and 'sludge." means sludge accumulated in a wastewater treatment process.
1000211 The term "solvent means a substance capable of dissolving another substance.
100022) The term "filtrate" means a liquid or gas that has been filtered.
(00023] The term "screw feeder" means a screw feeder such as a volumetric screw feeder or gravimetric screw feeder, capable of metering material in a production process, [00024 The term "filter press" means a machine using filtering cloths and plates to separate solids and liquids.
1000251 The term "biodiesel feedstoc "` means organic material used in the production of biofuels.
100026) The terms "about" and 'approximately" means a deviation of no greater than 16% from an absolute value.
100027): The term "substantially" means plus or minus 10%.
[00025] The term ' holding tank" means any piece of equipment that i used to store product, [00029] The term "%", unless otherwise specified, refers to percent by weight, f00030] The Wastewater sludge processing system takes sludge directly from the municipal waste water treatment plant, transforms it into useful products, and leaves no waste behind. It is a lowterr peratuÃre, low pressure process.
100031] The municipal solid waste (101) is transferred from treatment plant to a wet sludge holding bin (103). In the holding bin (103) the waste is 20-45%
solids by weight, The sludge is transferred by first screw feeder (105) to a dryer (107) where it is dried to 90% solids. During the drying, liquid is removed as steam (109). The dried sludge is then ground in a grinder (111), The dried ground sludge is transferred to a dried feed holding bin (203), The dried ground sludge is transferred by a screw feeder 5) along the path (100 1 A) to the path 1001 B) to the mixer reactor (113).
[00032] Solvent is added to the sludge in the mixer reactor (113) via pump a first pump (115). Within the mixer reactor (113) the mixture is mixed and heated.
The resulting material is viscous hydrocarbon and/or cellulose and minerals in suspension, The resulting solution is pumped by pump 21) into a filter press (117) where the filtrate and solids are separated. The filtrate which includes extracted oil, residual solvent, and traces of water, is sent to a holding tank (119).
The filtrate is pumped via a second pump (215 along the path (2005A.) to the path (2005B) to the heat exchanger (121). The filtrate is heated to the boiling point of the solvent and the boiling point of the residual water prior to entering the flash drum (123). In the flash drum (123), the solvent and residual water are evaporated and removed via the vacuum pump (125) The solvent-free oil Ãs collected from the bottom of the flash: drum (123) and moved by third pump (315) to a holding tank (127) ready for shipping as biodiesel feedstock.
100033) The solvent and residual water vapor from the vacuum pump (125) discharge and the vent lines from the upstream process along the path (2003A) to the path (2003B) are collected and are routed to the solvent recovery system indicated generally as (129), In the second heat exchanger (221) vapors are condensed back to a liquid state. The liquid then travels along the path (2001 A) to the path (2001 B) to the condenser/separator (131) which removes the water from the solvent. The water and the solvent are both returned to be reused in the process.
100034) The cellulose and minerals are moved from the condenser/separator (131) by a fourth pump (413) into the make-up solvent tank (133), The vented vapor from the condenser/separator (131) goes to an activated carbon canister (135) and then into the make-up solvent tank (133). Fresh solvent is also added to the make-up solvent tank (133). Hot water (13) is also removed from the condenser/separator (1 1 for reuse.
[00035] Back at the filter press (117), the cellulose/mineral mixture is collected and sent to a dryer (141) where the solvent is removed and recovered, The cellulose/mineral mixture proceeds to a holding tank (30$). The third screw feeder (305) takes the cellulose/mineral mixture along the path (2007A) to the path (200713) to a furnace (143) that provides heat for the process.
Optionally, the ash that remains can be processed for further byproduct recovery (145) or alternatively, it is used as a byproduct without further processing, 1000361 A nitrogen tank (147) uses the fifth pump (515) to move the nitrogen along the path (1001 A) to the path (10 113) to the mixer reactor (113), the filtrate tank (119), the dryer (141) and the dried cellulose bin (303).
('000,3 .? Preferably, the system does not employ further separation, but rather, the cellulose/mineral mixture is used as fuel in an alternative fuel furnace to dry the incoming sludge. The oil has a 19,000 enemy value and the cellulose/mineral mixture has a 7000 Stu/pound energy value.
['00038] The oil is considered to be a perfect feedstock for biodiesel. It is 80% fatty, acids (65% C16 and 018), and has almost no sulfur. It also can be used as fuel oil without further processing.
(00030] The process extracts 18`%% oil by weight from undigested sludge and 11 %
oil by weight. from digested sludge. Abone dry pound of sludge yields 11--13%
oil, 50-60% cellulose and 30% minerals (though the process need not separate the cellulose and minerals.
00O$0] The drying step of the process takes about 45% of the energy cost of the process, It should be rioted that because the process does not employ a washing step, drying costs are minimized, [00041] At the end of the process of the present invention, all the useful à at rials ll; cellulose and à inerals 1 a been ma tured. Most important, there is nothing left to be incinerated, landfill d, or otherwise disposed of, making the system of the present invention a truly zero-waste process.
[00042] The following examples are for illustrative purposes and are not indicative of the limits of the present invention.
EXAMPLE
100043] Process design Criteria and Assumptions Item Units Pesi _rÃ
100044] Municipal Solid Waste MSW) M SW Filter cake as feed to dryer Ib/hr 40 Moisture content % 75 Solids content % 25 Bulk density of MSW cake lb/ft' 85 Temperature (avg.) of NI SW cake 65 00045] Average Composition of Reactor Feed Solids Dried M: SW as feed to reactor lb/hr 10 Solids content % 80 Moisture uonte % 10 i1 (dry solids basis) % 10 Cellulose (dry solids) % 50-Bulk density of cellulose lbrft 11 Specific heat capacity Btu'lb--, 7550 Metal oxides (MO), . dry solids % 25-35 NT
Bulk density of MO lb/ft 156 . Gr. (average) of MO - 2.
Specific heat capacity of MO Btu/lb-+ 0.23 L000461 Average Composition of Metal Oxides iron oxide r 10.0 Calcium oxide % 6.25 Phosphorus oxide fz, 4.5 Aluminum oxide 2.25 Other oxides % 2.0 [000471 Solvent Characteristics l e t ne (C7H.16) Specific gravity 0-684 Bulk density of Ctft lb ft' 42.64 Boiling point of 0; H,i 209.1 Specific heat capacity of C7H,6 t `lb-.,F 0.5 Latent heat. of vaporization Btullb 76.45 Item Unit Din Nitrogen Gas Specific heat capacity of nitrogen Btu</lb_+ 0.25 Density of nitrogen WW' 0.073 1000481 Product Fuel Oil Specific gravity of oil - 0,9 Bulk density of oil Ili/W' 5 Specific heat capacity of oil Btu/ll - . 18,000 [000491 Plant Operation Length of shift hr/d 10 Operating hours per shift ter./shifts Dried MW feed processed Id/hr 10 Solvent addition Pounds per pound of dry solids lb/lb 41 Solvent loss/lb of product oil % 1.0 100050] MSW Feed to Dryer Raw MSW filter cake Ib/hr 40 Solids content % 25 Moisture content % 75 bulk. density of dried MSW cake ib ft' 21-31 Pilot Plant Operation Parameters 100051] The fixer/Reactor was si: ed * to process lb of solids on a dry basis (22.2 lb of dried MSW containing 90% solids) per batch of 3 hours duration.
Forty (40) pounds of dry solids processed during a shift contain an estimated 37.5% or 15 pounds of oil>. Approximately two (2) gallons of oil at 95%
recovery are to be produced during the hours of operation each day.
Number of shifts per day sh fts/d I
Duration of shift (total) hr/shiftlO
Number of batches per shift bate es:id 2 Reaction time per batch: hr/batch 3 Dried teed (90% solids) per batch I / batch 22.2 Dry solids content of Reactor feed Ib/batch 20 Solvent addition rate lb/batch 40 Solvent added lb/d' 80 Item Units Design [000521 Product Oil Oil in MW feed solids % 10 Oil content of MSW feed solids Ib d2 Estimated oil recovery % 95 Estimated oil recovery lb /d 14.25 Estimated oil recovery ai/ 1.9 100053] Mixer,/Reactor Solids processed on a dry basis 10 1b/batch Solvent (heptane) added per batch = 40 lb/batch Mass of dried feed (90% solids) charged to Mixer/Reactor (10 l / at h) (9 % solids) 111 lb batch Volume of dried feed charged to Mixer,'Reactor (11.I lb/bat ch)f(21-31 lb/ft) 0.35-.5 ft batch Volume of solvent (heptane.) added to Mixer/Reactor (40 lb/"batch)+(2'l. lb/ t ) .94 ft"/!batch Total volume of feed to Mixer/Reactor = 0.35-,52 ft" dried MS W filter c k + 1.88 "' heptane = 1,29-1 .46 ft`rbatch Size of Mixer/Reactor (D = diameter . height) ()x(D2) x (D) 1,29-1,46 ft':
D w 1(1.29-1.46) x (4 /tiff] >" - 1.1 -1.23 ft.
The Mixer/Reactor is I,5 ft. dia. x 2. ft. tall, which includes a freeboard allowance of 1.0 ft. and equipped with 1.0 h.p motor with variable frequency drive (FD). [4.42 ft$' 1000541 Broad Scope of the Invention 1,00055] Although the present invention has been fully described in conjunction with several embodiments thereof with reference to the accompanying drawings, it is to be understood that various changes and modifications may be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims, unless they depart therefrom.
1000561 While illustrative embodiments of the invention have been described herein, the present invention is not limited to the various preferred embodiments described herein, but includes any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term "preferably2z is non-exclusive and means "preferably, but not limited to." in this disclosure and during the prosecution of this application, means-plus-function or step plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation,, a) "means for" or "step for" is expressly recited; b) a corresponding: function is expressly recited; and c) structure, material or acts that support that structure are not recited. In this disclosure and during the prosecution of this application, the terminology "present invention" or "invention" may be used as a reference to one or more aspect within the present disclosure,. The language present invention or invention should not be improperly interpreted as an identification of criticality, should not be improperly interpreted as applying across all aspects or embodiments (i.e., it should be understood that the present invention has a number of aspects, and embodiments) and should not be, improperly interpreted as limiting the scope of the application or claims. In this disclosure and during: the prosecution of this application, the terminology "embodiment" can be used, to describe any aspect, feature, process or step, any combination thereof, and/or any portion thereof, etc.
In some examples, various embodiments may include overlapping features. In this disclosure, the following abbreviated terminology may be employed:' e.
.~t which means for example".
1000$] It has now been found that wastewater sludge can be processed economically by virtue of using products of the treatment process as a fuel for one or more heating steps in the process. It has further been found that wastewater sludge can be processed such that at the end of the process of the present invention, all. the useful materials-cil, cellulose and minerals-have been captured. Most important, it has still further been found that wastewater sludge can be processed such that there is nothing left to be incinerated, landfilled, or otherwise disposed of, making the system of the present invention a truly zero-waste process.
['009] In accordance with an em odiment of the invention, a zero-waste method of processing wastewater sludge is provide such that at the end of the process of oil, cellulose, and minerals have been captured and there is substantially nothing left to be incinerated. landfilied, or otherwise disposed of.
[00010] in accordance with another embodiment of the invention, a process is provide which comprises the steps of;
a- transferring sod wastewater sludge from a treatment plant to a wet sludge holding bin, said wastewater sludge containing from about 20 to 45%
solids by weight, b- drying said wastewater sludge to about 90% solids, grinding the dried wastewater sludge an transferring the dried ground sludge to a mixer rector, c- within the mixer reactor mixing the dried ground sludge with a solvent and heating to produce viscous suspension of hydà w.. arbons or cellulose and minerals in suspension, d- separating liquids and solids, e- heating the separated liquids to the boiling point of the solvent and the boiling point of the residual water prior and collecting evaporated solvent and residual water, f- transferring solvent-free oil to a holding tank, g- condensing evaporated solvent and residual water and separating water from solvent, and h- transferring separated solvent and residual water to the mixer reactor of step (c), 00011 In accordance with a further embodiment of the invention the step of separating liquids and solids is performed in a filter press, and further comprises the steps of;
i- collecting cellulose-mineral mixture from: said filter press drying said cellulose-mineral mixture and removing and collecting solvent 1<- reusing collected solvent in the process at step (c), and I- transferring dried cellulose/mineral mixture to a furnace and using the heat from the furnace in at least one of steps (b), (c) and ().
100012] In accordance with another embodiment of the invention the oil from step (f) is approximately 60% fatty acids, is approximately 65 weight % 1 and C18, and is substantially free of sulfur, [00013): In accordance with still another embodiment of the invention: the process extracts about 18% oil by weight from undigested sludge and 1'1% oil by weight from digested sludge.
100 014) In accordance with another embodiment of the invention the step of separating liquids and solids produces a filtrate comprising extracted oil, residual solvent, and traces of water, f00015] BRIEF DESCRIPTION THE DRAWINGS
10001) FIG., I is part I of the process flow diagram.
[00017] FIG. 2 is part 2 of the process flow diagram.
[00018] FIG, 3 is part of the process flow diagram.
DETAILED DESCRIPTION
[00019] it is advantageous to define certain terms before describing the invention.
It should be appreciated that the following definitions are used throughout this application.
Definitions [00020] The term "wastewater sludge" and 'sludge." means sludge accumulated in a wastewater treatment process.
1000211 The term "solvent means a substance capable of dissolving another substance.
100022) The term "filtrate" means a liquid or gas that has been filtered.
(00023] The term "screw feeder" means a screw feeder such as a volumetric screw feeder or gravimetric screw feeder, capable of metering material in a production process, [00024 The term "filter press" means a machine using filtering cloths and plates to separate solids and liquids.
1000251 The term "biodiesel feedstoc "` means organic material used in the production of biofuels.
100026) The terms "about" and 'approximately" means a deviation of no greater than 16% from an absolute value.
100027): The term "substantially" means plus or minus 10%.
[00025] The term ' holding tank" means any piece of equipment that i used to store product, [00029] The term "%", unless otherwise specified, refers to percent by weight, f00030] The Wastewater sludge processing system takes sludge directly from the municipal waste water treatment plant, transforms it into useful products, and leaves no waste behind. It is a lowterr peratuÃre, low pressure process.
100031] The municipal solid waste (101) is transferred from treatment plant to a wet sludge holding bin (103). In the holding bin (103) the waste is 20-45%
solids by weight, The sludge is transferred by first screw feeder (105) to a dryer (107) where it is dried to 90% solids. During the drying, liquid is removed as steam (109). The dried sludge is then ground in a grinder (111), The dried ground sludge is transferred to a dried feed holding bin (203), The dried ground sludge is transferred by a screw feeder 5) along the path (100 1 A) to the path 1001 B) to the mixer reactor (113).
[00032] Solvent is added to the sludge in the mixer reactor (113) via pump a first pump (115). Within the mixer reactor (113) the mixture is mixed and heated.
The resulting material is viscous hydrocarbon and/or cellulose and minerals in suspension, The resulting solution is pumped by pump 21) into a filter press (117) where the filtrate and solids are separated. The filtrate which includes extracted oil, residual solvent, and traces of water, is sent to a holding tank (119).
The filtrate is pumped via a second pump (215 along the path (2005A.) to the path (2005B) to the heat exchanger (121). The filtrate is heated to the boiling point of the solvent and the boiling point of the residual water prior to entering the flash drum (123). In the flash drum (123), the solvent and residual water are evaporated and removed via the vacuum pump (125) The solvent-free oil Ãs collected from the bottom of the flash: drum (123) and moved by third pump (315) to a holding tank (127) ready for shipping as biodiesel feedstock.
100033) The solvent and residual water vapor from the vacuum pump (125) discharge and the vent lines from the upstream process along the path (2003A) to the path (2003B) are collected and are routed to the solvent recovery system indicated generally as (129), In the second heat exchanger (221) vapors are condensed back to a liquid state. The liquid then travels along the path (2001 A) to the path (2001 B) to the condenser/separator (131) which removes the water from the solvent. The water and the solvent are both returned to be reused in the process.
100034) The cellulose and minerals are moved from the condenser/separator (131) by a fourth pump (413) into the make-up solvent tank (133), The vented vapor from the condenser/separator (131) goes to an activated carbon canister (135) and then into the make-up solvent tank (133). Fresh solvent is also added to the make-up solvent tank (133). Hot water (13) is also removed from the condenser/separator (1 1 for reuse.
[00035] Back at the filter press (117), the cellulose/mineral mixture is collected and sent to a dryer (141) where the solvent is removed and recovered, The cellulose/mineral mixture proceeds to a holding tank (30$). The third screw feeder (305) takes the cellulose/mineral mixture along the path (2007A) to the path (200713) to a furnace (143) that provides heat for the process.
Optionally, the ash that remains can be processed for further byproduct recovery (145) or alternatively, it is used as a byproduct without further processing, 1000361 A nitrogen tank (147) uses the fifth pump (515) to move the nitrogen along the path (1001 A) to the path (10 113) to the mixer reactor (113), the filtrate tank (119), the dryer (141) and the dried cellulose bin (303).
('000,3 .? Preferably, the system does not employ further separation, but rather, the cellulose/mineral mixture is used as fuel in an alternative fuel furnace to dry the incoming sludge. The oil has a 19,000 enemy value and the cellulose/mineral mixture has a 7000 Stu/pound energy value.
['00038] The oil is considered to be a perfect feedstock for biodiesel. It is 80% fatty, acids (65% C16 and 018), and has almost no sulfur. It also can be used as fuel oil without further processing.
(00030] The process extracts 18`%% oil by weight from undigested sludge and 11 %
oil by weight. from digested sludge. Abone dry pound of sludge yields 11--13%
oil, 50-60% cellulose and 30% minerals (though the process need not separate the cellulose and minerals.
00O$0] The drying step of the process takes about 45% of the energy cost of the process, It should be rioted that because the process does not employ a washing step, drying costs are minimized, [00041] At the end of the process of the present invention, all the useful à at rials ll; cellulose and à inerals 1 a been ma tured. Most important, there is nothing left to be incinerated, landfill d, or otherwise disposed of, making the system of the present invention a truly zero-waste process.
[00042] The following examples are for illustrative purposes and are not indicative of the limits of the present invention.
EXAMPLE
100043] Process design Criteria and Assumptions Item Units Pesi _rÃ
100044] Municipal Solid Waste MSW) M SW Filter cake as feed to dryer Ib/hr 40 Moisture content % 75 Solids content % 25 Bulk density of MSW cake lb/ft' 85 Temperature (avg.) of NI SW cake 65 00045] Average Composition of Reactor Feed Solids Dried M: SW as feed to reactor lb/hr 10 Solids content % 80 Moisture uonte % 10 i1 (dry solids basis) % 10 Cellulose (dry solids) % 50-Bulk density of cellulose lbrft 11 Specific heat capacity Btu'lb--, 7550 Metal oxides (MO), . dry solids % 25-35 NT
Bulk density of MO lb/ft 156 . Gr. (average) of MO - 2.
Specific heat capacity of MO Btu/lb-+ 0.23 L000461 Average Composition of Metal Oxides iron oxide r 10.0 Calcium oxide % 6.25 Phosphorus oxide fz, 4.5 Aluminum oxide 2.25 Other oxides % 2.0 [000471 Solvent Characteristics l e t ne (C7H.16) Specific gravity 0-684 Bulk density of Ctft lb ft' 42.64 Boiling point of 0; H,i 209.1 Specific heat capacity of C7H,6 t `lb-.,F 0.5 Latent heat. of vaporization Btullb 76.45 Item Unit Din Nitrogen Gas Specific heat capacity of nitrogen Btu</lb_+ 0.25 Density of nitrogen WW' 0.073 1000481 Product Fuel Oil Specific gravity of oil - 0,9 Bulk density of oil Ili/W' 5 Specific heat capacity of oil Btu/ll - . 18,000 [000491 Plant Operation Length of shift hr/d 10 Operating hours per shift ter./shifts Dried MW feed processed Id/hr 10 Solvent addition Pounds per pound of dry solids lb/lb 41 Solvent loss/lb of product oil % 1.0 100050] MSW Feed to Dryer Raw MSW filter cake Ib/hr 40 Solids content % 25 Moisture content % 75 bulk. density of dried MSW cake ib ft' 21-31 Pilot Plant Operation Parameters 100051] The fixer/Reactor was si: ed * to process lb of solids on a dry basis (22.2 lb of dried MSW containing 90% solids) per batch of 3 hours duration.
Forty (40) pounds of dry solids processed during a shift contain an estimated 37.5% or 15 pounds of oil>. Approximately two (2) gallons of oil at 95%
recovery are to be produced during the hours of operation each day.
Number of shifts per day sh fts/d I
Duration of shift (total) hr/shiftlO
Number of batches per shift bate es:id 2 Reaction time per batch: hr/batch 3 Dried teed (90% solids) per batch I / batch 22.2 Dry solids content of Reactor feed Ib/batch 20 Solvent addition rate lb/batch 40 Solvent added lb/d' 80 Item Units Design [000521 Product Oil Oil in MW feed solids % 10 Oil content of MSW feed solids Ib d2 Estimated oil recovery % 95 Estimated oil recovery lb /d 14.25 Estimated oil recovery ai/ 1.9 100053] Mixer,/Reactor Solids processed on a dry basis 10 1b/batch Solvent (heptane) added per batch = 40 lb/batch Mass of dried feed (90% solids) charged to Mixer/Reactor (10 l / at h) (9 % solids) 111 lb batch Volume of dried feed charged to Mixer,'Reactor (11.I lb/bat ch)f(21-31 lb/ft) 0.35-.5 ft batch Volume of solvent (heptane.) added to Mixer/Reactor (40 lb/"batch)+(2'l. lb/ t ) .94 ft"/!batch Total volume of feed to Mixer/Reactor = 0.35-,52 ft" dried MS W filter c k + 1.88 "' heptane = 1,29-1 .46 ft`rbatch Size of Mixer/Reactor (D = diameter . height) ()x(D2) x (D) 1,29-1,46 ft':
D w 1(1.29-1.46) x (4 /tiff] >" - 1.1 -1.23 ft.
The Mixer/Reactor is I,5 ft. dia. x 2. ft. tall, which includes a freeboard allowance of 1.0 ft. and equipped with 1.0 h.p motor with variable frequency drive (FD). [4.42 ft$' 1000541 Broad Scope of the Invention 1,00055] Although the present invention has been fully described in conjunction with several embodiments thereof with reference to the accompanying drawings, it is to be understood that various changes and modifications may be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims, unless they depart therefrom.
1000561 While illustrative embodiments of the invention have been described herein, the present invention is not limited to the various preferred embodiments described herein, but includes any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the present disclosure. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term "preferably2z is non-exclusive and means "preferably, but not limited to." in this disclosure and during the prosecution of this application, means-plus-function or step plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation,, a) "means for" or "step for" is expressly recited; b) a corresponding: function is expressly recited; and c) structure, material or acts that support that structure are not recited. In this disclosure and during the prosecution of this application, the terminology "present invention" or "invention" may be used as a reference to one or more aspect within the present disclosure,. The language present invention or invention should not be improperly interpreted as an identification of criticality, should not be improperly interpreted as applying across all aspects or embodiments (i.e., it should be understood that the present invention has a number of aspects, and embodiments) and should not be, improperly interpreted as limiting the scope of the application or claims. In this disclosure and during: the prosecution of this application, the terminology "embodiment" can be used, to describe any aspect, feature, process or step, any combination thereof, and/or any portion thereof, etc.
In some examples, various embodiments may include overlapping features. In this disclosure, the following abbreviated terminology may be employed:' e.
.~t which means for example".
Claims (8)
- Claim 1 A zero-waste method of processing wastewater sludge such that at the end of the process, oil, ceIlulose, and minerals have been captured and there is substantially nothing left to be incinerated, landfilIed, or otherwise disposed of, comprising the steps of:
a- transferring solid wastewater sludge from a treatment plant to a wet sludge holding bin, said wastewater sludge containing from about 20 to 45%
solids by weight, b- drying said wastewater sludge to about 90% solids, grinding the dried wastewater sIudge an transferring the dried ground sludge to a mixer reactor, c- within the mixer reactor mixing the dried ground sIudge with a solvent and heating to produce viscous suspension of hydrocarbons or cellulose and minerals in suspension, d- separating liquids and solids, e- heating the separated liquids to the boiling point of the solvent and the boiling point of the residual water prior and collecting, evaporated solvent and residual water, f- transferring solvent-free oil to a holding tank, g- condensing evaporated solvent and residual water and separating water from solvent, and h- transferring separated solvent and residual water to the mixer reactor of step (c). - Claim 2 The method of claim 1 , further comprising said step of separating liquids and solids is performed in a filter press, i- collecting cellulose-mineral mixture from said filter press j- drying said cellulose-mineral mixture and removing and collecting solvent k- reusing collected solvent in the process at step (c), and l- transferring dried cellulose/mineral mixture to a furnace and using the heat from the furnace in at least one of steps (b), (c) and (e).
- Claim 3 The method of claim 2, wherein the oil from step (f) is approximately 80%
fatty acids, - Claim 4 The method of claim 3, wherein the oil from step (f) is approximately weight % C16 and C18.
- Claim 5 The method of claim 3, wherein said oil is substantially free of sulfur,
- Claim 6 The method of claim 1, wherein the process extracts about 18% oil by weight from undigested sludge and 11% oil by weight from digested sludge.
- Claim 7 The method of claim 1, wherein said step of separating liquids and solids produces a filtrate, comprising extracted oil, residual solvent, and traces of water.
- Claim 8 Claim 1 A zero-waste method of processing wastewater sludge such that at the end of the process, oil, cellulose, and minerals have been captured and there is substantially nothing left to be incinerated, landfilled, or otherwise disposed of, comprising the steps of;
a- transferring solid wastewater sludge from a treatment plant to a wet sludge holding bin, said wastewater sludge containing from about 20 to 45%
solids by weight, b- drying said wastewater sludge to about 90% solids, grinding the dried wastewater sludge an transferring the dried ground sludge to a mixer reactor, c- within the mixer reactor mixing the dried ground sludge with a solvent and heating to produce viscous suspension of hydrocarbons or cellulose and minerals in suspension, d- separating liquids and solids, e- heating the separated liquids to the boiling point of the solvent and the boiling point of the residual water prior and coIlecting evaporated solvent and residual water, f- transferring solvent-free oil to a holding tank, g- condensing evaporated solvent and residual water and separating water from solvent, h- transferring separated solvent and residual water to the mixer reactor of step (c), i- collecting cellulose-mineral mixture from step (d), j- drying said cellulose-mineral mixture and removing and collecting solvent k- reusing collected solvent in the process at step (c), and 1- transferring dried cellulose/mineral mixture to a furnace and using the heat from the furnace in at least one of steps (b), (c) and (e), wherein the oil from step (f) is approximately 80% fatty acids and 65 weight %
C16 and C 18, and wherein said step of separating liquids and solids produces a filtrate comprising extracted oil, residual solvent, and traces of water,
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US22361709P | 2009-07-07 | 2009-07-07 | |
| US61/223,617 | 2009-07-07 | ||
| PCT/US2010/041245 WO2011005883A2 (en) | 2009-07-07 | 2010-07-07 | Wastewater sludge processing system |
Publications (1)
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| CA2768176A1 true CA2768176A1 (en) | 2011-01-13 |
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|---|---|---|---|
| CA2768176A Abandoned CA2768176A1 (en) | 2009-07-07 | 2010-07-07 | Wastewater sludge processing system |
Country Status (15)
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| US (1) | US20110162258A1 (en) |
| EP (1) | EP2451752A2 (en) |
| JP (1) | JP2012532746A (en) |
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|---|---|---|---|---|
| US20140001121A1 (en) * | 2012-04-18 | 2014-01-02 | Gene F. DeShazo | Method for Reclaiming Usable Products from Biosolids |
| JP6238543B2 (en) * | 2013-03-29 | 2017-11-29 | 株式会社クボタ | Organic sludge dewatering method |
| KR101338951B1 (en) * | 2013-04-23 | 2013-12-09 | 명지대학교 산학협력단 | Bioevaporation process for the zero-discharge treatment of highly concentrated organic wastewater |
| KR20150056429A (en) * | 2013-11-15 | 2015-05-26 | 김용환 | Treating Method of Sewage comprising sludge and waste water using solvent extraction |
| MY179289A (en) * | 2013-12-20 | 2020-11-03 | Ecophos S A | Method for recovering ash from waste incineration |
| MX2017003611A (en) | 2014-09-18 | 2017-11-17 | Bridgestone Corp | Extractor and related methods. |
| US20190225524A1 (en) * | 2016-06-11 | 2019-07-25 | Ii Victor A. Weir | Waste water solids separator system and method |
| EP3421575A1 (en) * | 2017-06-29 | 2019-01-02 | Aarhus Universitet | A method for biomass assisted separation of particulate matter from a liquid stream and upgrading of the combined solids |
| KR102138224B1 (en) | 2017-07-25 | 2020-07-27 | 고려대학교 세종산학협력단 | Method for producing biodiesel and solid fuel from wastewater sludge through hydrothermal treatment, and equipment thereof |
| CN110845101A (en) * | 2019-11-29 | 2020-02-28 | 湖南长岭石化科技开发有限公司 | Oily sludge harmless treatment system and treatment method thereof |
| FR3142681A1 (en) * | 2022-12-05 | 2024-06-07 | Universite Claude Bernard Lyon 1 | Process for separating fatty sludge by thermo-mechanical filtration |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4741840A (en) * | 1981-12-23 | 1988-05-03 | Exxon Research & Engineering Co. | Process for treating a sludge containing hydrocarbons |
| US5092983A (en) * | 1986-09-12 | 1992-03-03 | The Standard Oil Company | Process for separating extractable organic material from compositions comprising said extractable organic material intermixed with solids and water using a solvent mixture |
| US4906388A (en) * | 1988-11-09 | 1990-03-06 | Bechtel Group, Inc. | Sewage sludge dewatering process |
| JPH04197500A (en) * | 1990-11-28 | 1992-07-17 | Hosokawa Micron Corp | Method for drying water containing sludge |
| US5256251A (en) * | 1991-06-10 | 1993-10-26 | Hanover Research | Process for drying and solvent-extraction of solids and sludges |
| US5843311A (en) * | 1994-06-14 | 1998-12-01 | Dionex Corporation | Accelerated solvent extraction method |
| US6149802A (en) * | 1998-03-31 | 2000-11-21 | Toronto Star Newspapers Ltd. | Solvent recovery apparatus and method |
| US20040219400A1 (en) * | 2003-01-22 | 2004-11-04 | Said Al-Hallaj | Hybrid fuel cell/desalination systems and method for use |
-
2010
- 2010-07-07 EP EP10797801A patent/EP2451752A2/en not_active Withdrawn
- 2010-07-07 EA EA201200085A patent/EA201200085A1/en unknown
- 2010-07-07 CN CN2010800307880A patent/CN102471111A/en active Pending
- 2010-07-07 CA CA2768176A patent/CA2768176A1/en not_active Abandoned
- 2010-07-07 US US12/831,997 patent/US20110162258A1/en not_active Abandoned
- 2010-07-07 MA MA34512A patent/MA33415B1/en unknown
- 2010-07-07 BR BR112012000298A patent/BR112012000298A2/en not_active IP Right Cessation
- 2010-07-07 KR KR1020127000552A patent/KR20120120106A/en not_active Application Discontinuation
- 2010-07-07 SG SG2012000691A patent/SG177517A1/en unknown
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- 2010-07-07 JP JP2012519702A patent/JP2012532746A/en active Pending
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- 2012-01-04 ZA ZA2012/00043A patent/ZA201200043B/en unknown
- 2012-01-10 IL IL217451A patent/IL217451A0/en unknown
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Also Published As
| Publication number | Publication date |
|---|---|
| WO2011005883A2 (en) | 2011-01-13 |
| SG177517A1 (en) | 2012-02-28 |
| EP2451752A2 (en) | 2012-05-16 |
| WO2011005883A3 (en) | 2011-06-16 |
| JP2012532746A (en) | 2012-12-20 |
| ZA201200043B (en) | 2012-08-29 |
| CO6430452A2 (en) | 2012-04-30 |
| CN102471111A (en) | 2012-05-23 |
| KR20120120106A (en) | 2012-11-01 |
| MA33415B1 (en) | 2012-07-03 |
| IL217451A0 (en) | 2012-02-29 |
| BR112012000298A2 (en) | 2017-06-13 |
| CL2012000007A1 (en) | 2012-08-24 |
| EA201200085A1 (en) | 2012-10-30 |
| US20110162258A1 (en) | 2011-07-07 |
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