Upgrade & Expansion of Existing ETPs at Pulp & Paper Mills Marc Krieger IPPTA Conference – Kashipur 10-11 December, 2015 Director of Business Development.

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Presentation transcript:

Upgrade & Expansion of Existing ETPs at Pulp & Paper Mills Marc Krieger IPPTA Conference – Kashipur December, 2015 Director of Business Development – Asia-Pacific

Proprietary and confidential Increase of ETP capacity as a result of expansion of production activity in the mill  Increased production capacity  Additional production lines Improve effluent quality :  Reduce BOD, COD  Nitrification / de-nitrification (NH 4, TN)  Color reduction  ZLD implementation Problem Definition – When is ETP Upgrade / Expansion Required

Proprietary and confidential Main Challenges in ETP Upgrade / Expansion Technology upgrade to ensure meeting stricter compliance requirements Maximum utilization of existing infrastructure and ETP components : aeration tanks, clarifiers, air blowers, etc. Minimize the need for additional land allocation and civil works Minimize CAPEX

4 Proprietary and Confidential Traditional Solutions for Effluent Treatment - General  Low O&M cost  Simple to operate  Low effluent quality  Operation problems (odors)  Long SRT days = large area Extensive Oxidation pondsAttached GrowthSuspended Growth  Simple to operate  Resistant to shock loads (flow, toxicity)  Small footprint  Lower effluent quality  Simple process control  Operational problems (odors, clogging)  Good treatment  More space required  Complex operation / process control  Less resistant to shocks (load, toxicity) Intensive

Proprietary and confidential MBBR – Moving Bed Bi-Reactor Provides the process advantages of fixed film while eliminating the disadvantages, and enables achieving superior effluent quality Proven technology in the pulp & paper sector Increase of ETP capacity - in the range of % - when converting ASP to MBBR, or implementing MBBR before existing ASP Advantages of Biomass Carrier Technologies - MBBR

Proprietary and confidential Advantages of Biomass Carrier Technologies - MBBR Maximum design flexibility in upgrade / expansion of existing ETPs Maximum utilization of existing tanks = minimum requirement for additional footprint and civil works Simple & fast implementation : in most cases ETP operates throughout the upgrade works Staged investment : in “real time”, parallel to actual increase in mill capacity

Proprietary and confidential Recycled, high-density polyethylene Highly open external design > 650 m 2 /m 3 Effective surface area Optimal oxygen and nutrients transfer Applicable for various biological processes Aqwise Biomass Carriers protect biofilm against abrasion, ensures mass transfer efficiency and prevent clogging Innovation That Works

Proprietary and confidential  High effective surface area for biofilm growth : 650 m 2 /m 3  Openings in outer circumference create turbulent flow within the carrier, and minimize distance to biofilm from to mm across the entire media  10 year guarantee for mechanical integrity of the carrier, MoC : HDPE  Same media for all process stages Aqwise Biomass Carriers – Advantages to Remember

Proprietary and confidential High loadMedium load Aqwise Biomass Carriers - ABC Low load

10 Proprietary and Confidential Proprietary and confidential

11 Proprietary and Confidential RAS Sludge Treatment Problem Need to expand existing ASP to treat higher flow / load Solution MBBR upstream of the ASP to achieve COD & BOD reduction MBBR + ASP Configuration – Increasing ETP Capacity

12 Proprietary and Confidential RAS Sludge Treatment IFAS Configuration – Improving Effluent Quality Problem Need to upgrade existing ASP to achieve Nitrogen removal Solution Simultaneous BOD and Nitrogen removal Internal Recirculation

13 Proprietary and Confidential Oxidation pond MBBR Configuration – Effluent Polishing Reservoir BOD Polishing and Nitrification Problem Need to upgrade ETP to achieve improved effluent quality (BOD & Ammonia) Solution Addition of MBBR unit for BOD polishing and nitrification

14 Proprietary and Confidential REQUIREMENTS SOLUTION HIGHLIGHTS Customer: Location: Capacity: Proprietary and confidential Case Study: Pulp & Paper Paper Factory, Italy Europaper Italy 2,000 m 3 /d Addition of production lines led to increase of wastewater capacity and BOD loads AGAR® MBBR installed upfront of existing effluent treatment plant (RBC + clarifier)

15 Proprietary and Confidential

16 Proprietary and Confidential CASE STUDY – Valdivia CMPC Chile, 2006 DAF-MBBR Configuration (8,500 m 3 /d) Client: Large pulp and paper factory in Chile Production: Thermo Mechanical Pulping; paper board Wastewater flow: 8,500 m 3 /d Challenges: Upgrade an existing plant – flow increase from 4,500 to 8,500 m 3 /d, within limited footprint Effluent requirement: Discharge to river Design: DAF – MBBR - DAF Results: Successful upgrade with low HRT

17 Proprietary and Confidential CASE STUDY – Valdivia CMPC Chile, 2006 DAF - MBBR Configuration (8,500 m 3 /d) HRT = 2 h ValueParameter 680BOD in [mg/l] 300BOD out [mg/l] required 260BOD out [mg/l] actual

18 Proprietary and Confidential CASE STUDY – Valdivia CMPC Chile, 2006 DAF - MBBR Configuration (8,500 m 3 /d)

Proprietary and confidential Color – typically in pulp mills  Originates from lignins in natural raw materials (wood chips), or from dyes (colored tissue paper)  Not completely bio-degradable – residual color after the biological stage  Requires additional physico-chemical treatment stage after the biological reactor : clari-flocculator, DAF Hardness  Originating from calcium-based chemicals used in the paper making process  Potential for precipitation on the carriers – scaling. Will impact carrier weight / mixing

20 Proprietary and Confidential Proprietary and confidential What Everyone Wants to Know – How Much Does it Cost ??? And, of course, there is no “simple” answer. Will be determined case by case based on :  Effluent characteristics : flow & quality  Effluent quality requirements : discharge to environment, ZLD, irrigation  Existing ETP infrastructure : technology, age, level of operation & maintenance

21 Proprietary and Confidential Contact Information Marc Krieger Director of Business Development – Asia-Pacific Website Telephone

Company Highlights

Proprietary and confidential About Aqwise Aqwise is an industry leader in advanced bio-film based water and wastewater treatment technologies  Expertise – Strong biological process know-how – Multi-disciplinary expert staff  Global Reach, Local Presence – Over 350 installations in 40 countries – World-wide regional offices, sales representatives and partners

Proprietary and confidential Global Solution Provider Aqwise is a trusted solution provider for municipal and industrial customers > 180 Municipal Installations > 40 Countries Worldwide > 170 Industrial Deployments

Proven Track Record of Success Over 350 installations worldwide Municipal: New plants Upgrade Expansion Industrial: Food & Beverage Pulp & Paper Pharmaceutical Oil & Gas

Over 350 diverse installations worldwide Proven Track Record of Success

Proprietary and confidential Strong Customer Base Aqwise technology solutions are used by many global brands and industry leaders

Proprietary and confidential Research & Development Aqwise is actively involved in the development of new and innovative biological solutions Field Test Facilities  Research Facilities – Advanced Research & Development center located in Israel – Biological process excellence center  Wastewater Treatment – Development of new biological processes for treatment and compliance to new standards  Drinking Water – Focus on efficient treatment of various pollutants Aqwise Laboratories

Proprietary and confidential Customer Benefits / DURABLE & STABLE Highly resistant to hydraulic shock loads with short recovery time after toxic loads LOW MAINTENANCE Simple process control Low maintenance & operational costs ECO FRIENDLY Carriers manufactured from recycled HDPE, minimal land usage, reduced sludge generation SMALL FOOTPRINT Suitable for both new applications and existing plant upgrades COST EFFICIENT Requires minimal civil works, short project life cycle and low CAPEX/OPEX SCALABLE & FLEXIBLE Smooth upgrade or gradual expansion based on just-in-time investment

Proprietary and confidential Business Models Aqwise offers a wide range of business models to fit customer needs Process Package Process and detailed engineering design services, carrier and equipment supply Turn-Key Project Full project management and implementation Professional Services On-site pilot demonstration, process start-up and supervision, full after-sales support Financing Tailor-made financial models to meet customer budget requirements Package Plant Compact containerized and pre- fabricated solutions

Aqwise in India

Proprietary and confidential Activity in India to Date  First projects in public sector, with Indian EPC company : STP 30 MLD, WTP 160 MLD (Agra)  Permanent presence in India since May 2014, based in Delhi  Focus on industrial / private sector : ETP upgrades & expansions  Projects to date :  ETP expansion for Teva API  MBBR technology demonstration – Hindustan Unilever  Advanced stages of negotiations with clients in pulp & paper, food & beverage, pharma & chemical sectors

Proprietary and confidential Case Study: Pharma - API  Upgrade and expansion of an existing ETP (Effluent Treatment Plant) at an API facility in India  Conversion of activated sludge process to 3-stage MBBR in existing reactor  Addition of DAF after existing clarifier to improve effluent quality : pre-treatment to UF/RO for ZLD  Aqwise scope of supply :  Supply of MBBR media and screens, DAF unit  All process and detailed design  Project management and site supervision of local contractor  Completed Q3 2015

REQUIREMENTS SOLUTION HIGHLIGHTS Customer: Location: Capacity: Proprietary and confidential Case Study: Surface Water Treatment Drinking Water Treatment Plant - Agra, India Triveni Engineering & Industries Yamuna River - Agra, India 163,000 m 3 /d (MBBR) Modernization of existing drinking water plant, serving population of 2 million people Cost-efficient surface water treatment AGAR® MBBR and UF membrane polishing Efficient COD reduction and BNR Adaptive to variable loads Minimized chlorine dosing