US20220227665A1 - A Method and Apparatus for Processing Water Treatment Residuals - Google Patents

A Method and Apparatus for Processing Water Treatment Residuals Download PDF

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US20220227665A1
US20220227665A1 US17/613,850 US202017613850A US2022227665A1 US 20220227665 A1 US20220227665 A1 US 20220227665A1 US 202017613850 A US202017613850 A US 202017613850A US 2022227665 A1 US2022227665 A1 US 2022227665A1
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residuals
heating
temperature
heating chamber
heated
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Mark Russell
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Ardex Group GmbH
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Ardex Group GmbH
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    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00637—Uses not provided for elsewhere in C04B2111/00 as glue or binder for uniting building or structural materials
    • C04B2111/00646—Masonry mortars
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/60—Flooring materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23G—CREMATION FURNACES; CONSUMING WASTE PRODUCTS BY COMBUSTION
    • F23G2201/00—Pretreatment
    • F23G2201/20—Dewatering by mechanical means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B7/00—Rotary-drum furnaces, i.e. horizontal or slightly inclined
    • F27B2007/005—Rotary-drum furnaces, i.e. horizontal or slightly inclined for the treatment of slurries or wet materials
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
    • Y02P40/121—Energy efficiency measures, e.g. improving or optimising the production methods
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
    • Y02P40/125—Fuels from renewable energy sources, e.g. waste or biomass
    • 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
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W10/00—Technologies for wastewater treatment
    • Y02W10/30—Wastewater or sewage treatment systems using renewable energies
    • Y02W10/37—Wastewater or sewage treatment systems using renewable energies using solar energy
    • 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
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W10/00—Technologies for wastewater treatment
    • Y02W10/40—Valorisation of by-products of wastewater, sewage or sludge processing
    • 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
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • This invention relates to a method and apparatus for processing water treatment residuals or other amorphous aluminium oxide or aluminium hydroxide rich waste residuals to provide raw materials for use in the manufacture of hydraulic binders for construction and related applications, in particular calcium aluminate containing hydraulic binders.
  • WTR Water treatment residuals
  • a flocculant typically comprising aluminium compounds such as aluminium sulphate (Al 2 (SO 4 ) 3 .14H 2 O), commonly referred to as Alum, or ferric aluminium sulphate (ferrum).
  • Coagulation removes particles suspended in natural, untreated water.
  • the chemical reaction involved comprises:
  • WTR aluminium rich waste slurry
  • WTR consist of water, organic material, remnant flocculant and other minor components.
  • WTR is a good source of amorphous aluminium oxide and/or amorphous aluminium hydroxide.
  • water treatment residuals can be understood in particular as drinking water treatment residuals, which can be purified much more easily than other residuals, such as waste water treatment residuals or the like, in particular because they are less contaminated. Because of the different ingredients of drinking water and wastewater, these (drinking water/wastewater) are not directly comparable.
  • amorphous can be understood and explained in particular with respect to the degree of crystallisation.
  • the degree of crystallization can thereby serve as a measure of the amorphous character of a material, the properties being anti-proportional to one another.
  • amorphous aluminium oxide or aluminium hydroxide rich waste residuals according to the invention have a degree of crystallisation of less than 25 wt. %, preferably less than 20 wt. %, in particular less than 15 wt. %.
  • the degree of crystallization can be measured, for example, by spectroscopic methods, DSC measurements or X-ray diffraction experiments.
  • a method for processing water treatment residuals or other amorphous aluminium oxide or aluminium hydroxide rich waste residuals for use in the manufacture of hydraulic binders comprising heating the residuals to remove water and oxidise organic material contained therein, comprising controlling the temperature of the residuals such that they are heated to a temperature no higher than 800° C.
  • the method comprises controlling the temperature of the residuals such that they are heated to a temperature no higher than 700° C., more preferably no higher than 650° C.
  • the method comprises controlling the temperature of the residuals such that they are heated to a temperature between 350° C. and 650° C., more preferably to a temperature between 400° C. and 500° C.
  • any aluminium oxide or aluminium hydroxide in the residuals remains in its amorphous and therefore reactive state and therefore remains useful in the manufacture of hydraulic binders.
  • the residuals may be heated in a heating chamber, the temperature of the residuals being controlled by the addition of air and/or water to the chamber and/or by controlling the heat supplied to the heating chamber by a heating means by a temperature control means.
  • air is added to the heating chamber at a rate adapted to ensure that substantially all organic material in the residuals are oxidised.
  • the residuals within the heating chamber may be heated indirectly by heating an exterior of the heating chamber and/or the exterior of the heating chamber is heated by means of burners acting directly on the exterior of the heating chamber.
  • the heating chamber is located within a heating jacket receiving hot gases from a burner.
  • the residuals are at least partially dewatered prior to heating.
  • the residuals may be dewatered via a mechanical process, such as a belt dryer and/or rotary dryer.
  • the residuals are dewatered to have a water content of between 20% and 40%.
  • the residuals may be milled and/or ground after heating to a particle size of 40 microns or approximately 40 microns.
  • the residuals may be hydrated after heating to convert amorphous aluminium oxide to amorphous aluminium hydroxide.
  • the residuals in particular after heating, may be mixed with a source of calcium ions and a source of sulphate ions in the presence of water to form ettringite.
  • the residuals in particular after heating, may be mixed with Portland cement, hydrated lime and calcium sulphate in the presence of water.
  • the residuals in particular after heating, may be mixed with a source of calcium ions in the presence of water to form calcium aluminates.
  • the residuals may be mixed with a source of calcium ions and a source of sulphate ions in the presence of water to form calcium aluminates and calcium sulphoaluminates.
  • an apparatus for processing water treatment residuals or other amorphous aluminium oxide or aluminium hydroxide rich waste residuals for use in the manufacture of hydraulic binders comprising a heating chamber within which the residuals can be heated, means for heating the heating chamber and means for controlling the temperature therein.
  • an apparatus in accordance with the invention has the same advantages as described in detail above regarding the inventive method.
  • An apparatus designed in this way is particularly advantageous because it allows for the use of water treatment residuals in the manufacture of hydraulic binders for construction and related applications, in particular calcium aluminate containing hydraulic binders.
  • the heating chamber may be heated by burners acting against an outer wall of the heating chamber and/or the heating chamber may be heated by ducting hot gases from a combustion chamber into a heating jacket surrounding the heating chamber.
  • combustion gases from the heating means may be used to pre-heat the air added to the heating chamber.
  • the heating chamber may be adapted to be rotated during heating.
  • the heating chamber comprises a tubular drum mounted for rotation about a longitudinal axis and having an inlet at one end and an outlet and an opposite end.
  • the apparatus may further comprise a dewatering means upstream of the heating chamber for reducing the water content of the residuals.
  • the apparatus may further comprise a milling and/or grinding means downstream of the heating chamber for reducing the particle size of the residuals after heating.
  • the temperature control means is adapted to limit the temperature of the residuals to no more than 700° C., more preferably to no more than 650° C.
  • the temperature control means may be adapted to control the temperature of the residuals in the heating chamber to between 350° C. and 650° C., more preferably to between 400° C. and 500° C.
  • FIG. 1 is a schematic view of an apparatus for processing residuals in accordance with the present invention.
  • FIG. 2 is a transverse sectional view through the apparatus of FIG. 1 .
  • the method comprises the steps of
  • Moisture Removal residuals from a water treatment process or other amorphous aluminium oxide or aluminium hydroxide rich waste residuals may be initially filter pressed in filter beds, typically at the water treatment plant, whereby the moisture content of the residuals may be reduced to 60-80%. Further moisture is preferably removed by mechanical drying, for example using a belt dryer or rotary dryer, or drying using solar energy under poly tunnels, to produce residuals having a water content of between 20% and 30%.
  • Thermal Treatment The partially dried residuals are then heated to between 350° C. and 800° C. to remove (burn off) organic carbon content without reaching a temperature high enough to convert amorphous Aluminium Oxide or Aluminium Hydroxide present in the residuals to its crystalline unreactive state.
  • the equipment used for the thermal treatment step may comprise an indirect rotary calciner, as illustrated in the drawings (although other thermal treatment technologies are envisaged).
  • the optimum processing temperature is preferably no higher than 800° C., more preferably no higher than 650° C., to ensure that aluminium compounds in the residuals, in particular aluminium oxide and aluminium hydroxide, remain in an amorphous state. At temperatures greater than 800° C. such amorphous aluminium compounds begin to convert to a crystalline unreactive form. Based on carbon removal efficiency balanced against cost the preferred thermal treatment temperature is between 400° C. and 500° C.
  • heating may be carried out in a drying chamber 2 of an indirect rotary calciner, wherein the products of combustion do not come into direct contact with the residuals being treated. Heat is transferred to the residuals by conduction and radiation through the wall of the drying chamber 2 .
  • the drying chamber 2 may be heated by burners 4 positioned in a heating jacket 6 around the outer wall of the drying chamber 2 , as illustrated in FIG. 1 , or by the use of a separate combustion chamber from which hot gases are ducted to the heating jacket 6 mounted around the drying chamber 2 .
  • Additional process air A is preferably blown into the drying chamber to provide additional oxygen for complete combustion of organic material within the residuals.
  • the added air may also be used to control the temperature within the chamber.
  • the process air may be introduced to the drying chamber via an air sparge pipe 8 .
  • Each kg of carbon requires 2.67 Kg of O 2 for complete combustion. Therefore a process air flow rate of 9m3 of air per hour per kg of carbon in the feed slurry is preferred.
  • a heat exchanger may be used to recover heat from a combustion exhaust to pre-heat the process air before it enters the drying chamber.
  • the drying chamber 6 may be rotated and may contain paddles 10 to break up and mix the residuals during heating.
  • Milling After the thermal treatment the residuals, in the form of ash, are ground or milled, preferably to particle sizes of approximately 40 micron.
  • Hydration The above process will form a product that contains amorphous aluminium oxide which can be successfully used as a component in cementitious binder. However, for some applications amorphous aluminium hydroxide is required. In such cases the product may be hydrated much in the same way as powdered hydrated lime is produced from lime. Hydration may happen before or after the milling stage.
  • a source of calcium ions may be added to the residuals, preferably after heating or alternatively before heating, to form calcium aluminates in the presence of water.
  • the residuals typically have a calorific value of around 7 MJ/Kg and as a result may provide a source of fuel during combustion.
  • the product produced from the processed residuals consists predominately of amorphous aluminium oxide and/or amorphous aluminium hydroxide (typically 75 to 80% amorphous aluminium oxide).
  • the remaining components primarily varying amounts of quartz, iron oxide and some residual carbon are essentially inert fillers.
  • the amorphous aluminium oxides/hydroxides remaining in the treated residuals can react to form cementitious minerals.
  • Ettringite (Ca 6 [Al(OH) 6 ] 2 (SO 4 ) 3 .26H 2 O) may be formed when the treated residuals are mixed with a source of calcium ions (e.g. Portland cement, hydrated lime) and a source of sulphate ions (e.g. calcium sulphate) in the presence of water.
  • a source of calcium ions e.g. Portland cement, hydrated lime
  • sulphate ions e.g. calcium sulphate
  • Calcium aluminate hydrates may be formed when the treated residuals are mixed with a source of calcium ions (e.g. Portland cement, hydrated lime) in the presence of water.
  • a source of calcium ions e.g. Portland cement, hydrated lime
  • the processed residuals may be used in the manufacture of floor screed. It has been found that the processed residuals, particularly in the form of Ettringite, exhibit shrinkage compensating characteristics. As such, the product produced from the processed residuals can be a direct competitor to Portland cement or anhydrite based screeds.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Water Supply & Treatment (AREA)
  • Hydrology & Water Resources (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Civil Engineering (AREA)
  • Thermal Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Geology (AREA)
  • General Chemical & Material Sciences (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Processing Of Solid Wastes (AREA)
  • Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)
  • Catalysts (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
  • Adhesives Or Adhesive Processes (AREA)
US17/613,850 2019-06-12 2020-06-12 A Method and Apparatus for Processing Water Treatment Residuals Pending US20220227665A1 (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
GB1908383.1 2019-06-12
GB1908383.1A GB2586951B (en) 2019-06-12 2019-06-12 A method and apparatus for processing water treatment residuals
GB2003674.5A GB2592985A (en) 2019-06-12 2020-03-13 A method for the manufacture of hydraulic binders from water treatment residuals
GB2003674.5 2020-03-13
PCT/EP2020/066313 WO2020249736A1 (en) 2019-06-12 2020-06-12 A method and apparatus for processing water treatment residuals

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US17/612,358 Pending US20220242788A1 (en) 2019-06-12 2020-06-12 Use of a Hydraulic Binder Containing Calcium Aluminate for the Production of a Construction Material
US17/613,850 Pending US20220227665A1 (en) 2019-06-12 2020-06-12 A Method and Apparatus for Processing Water Treatment Residuals
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