Literally “Making gold out of shit”... Open Source: Sewage Sludge Carbonisation by small public utility for wastewater in East-Germany, ZV F...

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Literally “Making gold out of shit”...

Open Source: Sewage Sludge Carbonisation by small public utility for wastewater in East-Germany, ZV Frohnbach, by Dr. Steffen Heinrich, for larger wwtp!?

Dear All,

First of all, I or public utility ZV Frohnbach from East-Germany, do not want to sale anything to you.

I just want to let you and on other levels, to know about an Open Source (“copy-paste” of a "detailed documentation of the process tested in Niederfrohna, East-Germany with explanations of the system technology, technical data, material and energy balances, operational experience and economic considerations was compiled in a specialist book, with digitized additional information (calculation aids, documents and videos)") of a simple "Sewage Sludge Carbonisation" by a small public utility for wastewater treatment from East-Germany, by Dr. Steffen Heinrich, an East-German friend of mine (location: 50°52'39.33"N, 12°44'55.16"E).

This public utility is using since ~2-3 years a purposly simple Pyrolysis-Carbonisation system by making use of the inert sludge energy to do drying and pyrolysis, without extra energy inputs! Only for the startup of main processes an external energy input is needed. All machine components are "just from the shelf", German made. This pilot plant on just ~340 m2 ground for ~40,000 PE wwtp is now running since ~2-3 years without any problems.

See pdf's, pictures and 4 videos in English language at link:

https://www.mediafire.com/folder/0fwztczs2r7tg/Sewage_Sludge_Pyrolyse

This pilot plant costed ~3.2 MEURO, a possible “copy-past”-plant would cost "only" ~1.5 MEURO, as it is now ready for “copy-paste”. Under German law-condition this small public utility is now saving every year ~250,000 EURO by not transporting and burning the surplus sludge any more. In opposition to that former endeavour, they give it now to farmers/gardeners for free as soil enhancer, as by German law any public utility is not allowed to sale anything for extra-profit.

Maybe decision makers have a look in this simple "Sewage Sludge Carbonisation" details and pick up this Open Source (no licence fees!) idea for public utilities financial advantages and for industries too. Avoiding future sludge waste costs by generating profits and healthy soils through this “farm-gold”.

Literally “Making gold out of shit”...


Best Regards,

Detlef SCHWAGER

PS:

What to do with the sewage sludge?

Rising disposal costs, no disposal capacities, new laws and regulations breathing down your neck - what to do?

Sewage sludge pyrolysis as an economical and environmentally friendly alternative

The public utility ZV Fronbach, Dr. Steffen Heinrich and infraplan-ingenieure.de have developed together a new concept for its municipal sewage treatment plant with a treatment capacity of ~40,000 PE and carried out several large-scale tests for both drying and pyrolysis. The focus was on the integration of all available energy sources (sewage gas, electrical energy and waste heat from CHP) in order to achieve an acceptable energy and CO2 balance. The concept is scalable and therefore also suitable for wastewater treatment plants of any size from 10,000 PE.

Model project for the Free State of Saxony

It is important to the Free State of Saxony to demonstrate options for future sewage sludge disposal. This is why the Free State supported the model project "Construction of a pyrolysis plant for sewage sludge utilisation" of the Frohnbach special purpose association. Realisation at the Niederfrohna sewage treatment plant started back in 2018. The centrepiece is the drying and pyrolysis unit, which is integrated into the existing sewage treatment plant site. The amount of sewage sludge is reduced by around 90% from ~1,450 tonnes per year to less than ~170 tonnes of biochar per year. This contains over ~20 tonnes of valuable phosphorus per year.

Advantages for the sewage treatment plant operator:

- Independence from price increases and disposal routes
- Decentralised solution, can therefore be used at any wastewater treatment plant
- No need to change the existing treatment process
- Significant reduction in the volume of sewage sludge
- Elimination of costly sewage sludge transport (~75% water!)
- Heat recovery with pyrolysis gas or utilisation of process heat for sewage treatment plant operation (local heating network, digestion, drying)
- Biochar is used to improve soils (> 9 Ma.-% of biochar contains N, Mg, S, Si, K, P, Ca)
- Biochar can be stored well as a sterile and dry product
- Basis for other phosphorus recovery processes

Sewage sludge pyrolysis becomes more energy efficient the better the sewage sludge is pre-dried (at least ~80 to 90% dry matter). It is particularly promising to use undigested sewage sludge. Because this has almost twice the energy content compared to residual sludge from digestion towers. However, depending on the drying process, increased odour pollution must be expected.