FULL SCALE BIOREFINERY AND TERRITORIAL STRATEGY FOR RESOURCE RECOVERY AND REUSE The Gruppo CAP Case Study SUMMARY GRUPPO CAP FROM THE SUSTAINABILITY PLAN TO THE MASTER PLAN A LIVING LAB TO TRAIN OUR TEAMS FIRST OUTCOMES THE BIOREFINERY DIGITALIZATION AND NETWORKING AS ENABLERS CONCLUSIONS GRUPPO CAP Investments of the italian water utilities – benchmark 2017 Investiments on Investments population on revenues Medium/Big Water 34 €/p.c. 22% Utilities* CAP Holding 46 €/p.c 33% GRUPPO CAP - SUSTAINABILITY PLAN 2033 https://sostenibilita.gruppocap.it/application/files/5515/5964/3927/CAP_Piano_sostenibilita_2033.pdf THE MASTER PLAN ▪ Gruppo CAP provides municipal water and wastewater services Biopolimeri PHA (ton/anno) to over 2 million inhabitants, producing in 61 waste-water treatment plants where almost 80.000 ton/year dewatered Fosforo come struvite (ton/anno) sludge is produced. Totale GRUPPO CAP ▪ In such a scenario Gruppo CAP can and wants to deliver a Peschiera B. circular economy approach. To this aim Gruppo CAP has defined Sesto S.G. a territorial Master Plan to implement eco-innovative and energy-efficient solutions to Robecco ▪ renovate and innovate existing wastewater treatment Bresso plants Pero ▪ close the circular value chain by applying low-carbon techniques to recover materials that are otherwise lost. 0 500 1000 1500 ▪ The existing municipal wastewater treatment plants can be renovated and integrated to become multi- purpose urban biorefineries that serve the citizens to treat and valorize municipal waste streams, such as wastewaters and organic waste, towards a coherent urban strategy ▪ In order to include leading edge sustainable solutions, the Master Plan (50 M€ budget) considers synergic interaction with large ongoing European Horizon2020 innovation actions, such as the “SMART-Plant” and the “Digital Water Cities” projects ▪ Existing anaerobic digesters will be valorized towards the best exploitation of the existing reaction volumes, industrial symbiosis opportunities will be explored in order to provide better and cheaper services to our customers THE NETWORK – OUR PLANTS Bresso Sesto San Giovanni Turbigo Perform Water 2030 Perform Water 2030 Industrial effluents CHP and biomethane Thermal valorization of sewage sludge Truccazzano and P-recovery Anaerobic digestion Anaerobic for organic matters digestion for CHP and biomethane organic matters Pero Anaerobic digestion Grit and sands CHP and biomethane for organic matters + valorization VFA Perform Water 2030 Idroscalo – Heating distrcits research center Anaerobic digestion Perform Water Peschiera for organic matters 2030 Settala Fertilizers Robecco Fertilizers CHP Grit and sands valorization Bareggio Rozzano San Giuliano Anaerobic digestion Perform Water Solar for organic matters Fertilizers 2030 CHP Trezzano Solar 6 THE NETWORK – PERFORM WATER 2030 LIVING LAB http://www.performwater2030.it WORKING PACKAGES - ENERGY 2017 2018 2019 ROBECCO 4.564.839 kwh produced 6% of the WWTP COGENERATION BRESSO SESTO consumption PESCHIERA 13.000 MWh DISTRICT HEATING PERO estimated production BRESSO Bresso 558 cars (15.000 km/y) BIOMETHANE PERO Pero 340 cars TREZZANO 217.840 kWh produced PHOTOVOLTAICS BAREGGIO (estimation 2019) 6% of the WWTP consumption WORKING PACKAGES: NUTRIENTS LINEA DI AZIONE 2017/2018 2019 2020 Conversion of existing volume SESTO (thickeners) -> Sludge fermentation: VFA 1ton VFA/d (Sesto) + 1ton VFA/d ROBECCO (Robecco) to be resued in substitution of C (moving towards SCENA-SMART PLANT process) From biogas desulphurisation -> 1500 kgS/year BRESSO SULPHUR RECOVERY Ongoing test for concentration and recovery PESCHIERA SAN 28% of our sludge in 2018 became FROM SLUDGE TO GIULIANO compost (mixed with garden ROZZANO FERTILIZERS waste) or fertilizer (calcium carbonate) 69.268.550 m3/year (21.8% total vol) REUSED 15 PLANTS WASTEWATER 2 plants direct reuse for agricultural and civil purpose (street washing trucks) 13 plant indirect agricultural water reuse But…..what about phosphorus? PHOSPHORUS RECOVERY IN THE CAP AREA ▪ The average concentration of phosphorus in the sewage sludge produced in Lombardy is 2.10% (as Ptot), in line with the value of the 75th percentile of the sample on a national scale. ▪ The average ash fraction in the sludge of the same sample is about 30%, leading to an estimate of 7% Ptot in sludge ashes or 16% as P2O5. ▪ In Italy, almost all wastewater treatment plants (WWTPs) do not operate biological phosphorus removal -> low phosphate content in centrate (30-60 mgP/L) ▪ In Italy, 98% of the wastewater plants are under 100.000 PE ▪ There are two main reasons that make phosphorus recovery from the water line less attractive in Italy if compared to other typical situations in Northern Europe: – Firstly, in the WWTPs considered, influent P concentration is about 4-5 mg/l, lower than the reference system considered for the assessments in Northern Europe WWTPs, usually about 8-9 mg/l. – Secondly, the use of iron and aluminium salts for the chemical precipitation of phosphorus is widely used. Source: R. Canziani and R. Di Cosmo 2018 - STATO DELL’ARTE E POTENZIALITÀ DELLE TECNOLOGIE DI RECUPERO DEL FOSFORO DAI FANGHI DI DEPURAZIONE – Ingegneria dell’Ambiente vol 5 3/2018 SLUDGE DISPOSAL STRATEGIES DESTINATION 2015 2016 2017 2018 ▪ From 2016 we have redesigned our strategies with a «zero-landfill» approach. AGRICOLTURE 56,0% 77,4% 69,7% 51,1% LANDFILL 40,0% 16,2% 1,1% 1,3% CEMENT INDUSTRY 4,0% 2,3% 4,7% 3,6% ▪ From July 2016, due to some market negative FERTILIZERS 0,0% 0,0% 5,0% 28,1% externalities, we have pushed on sludge to CO-INCINERATION 0,0% 4,1% 19,4% 15,9% fertilizers solutions increasing, at the same time, sludge co-incineration. DESTINATION 100,0% ▪ From 2017, sludge disposal in landfills is < 1,5% 50,0% ▪ 8 changes in legislation in less than 4 years… 0,0% 2015 2016 2017 2018 - budget ▪ Disposal costs are increasing RECUPERO SMALTIMENTO PRODOTTO 90 000 140 ▪ Unit costs by destination are now flat with no 129 130 80 000 120 correlation with potential nutrients/energy 70 000 109 110 100 100 recovery opportunities 60 000 94 90 50 000 84 80 75 70 40 000 60 €/ton ton/year 30 000 50 ▪ From 2018 several water utilities have started 40 20 000 30 sending sludges to other EU countries (200 20 10 000 10 €/ton) - - ▪ How long would it be sustainable without new strategies? SLUDGE PRODUCTION (ton/year) Average cost (€/ton) THE BIOREFINERY OBJECTIVE Transforming the existing municipal waste incineration plant into a biorefinery for sludge (65.000 ton/y) and OFMSW (30.000 ton/y) treatment and for nutrients/energy recovery THE OPPORTUNITY 6000 t/y 30.000 t/y digestate to OFMSW compost 62.000 t/y sludge + 220 mc/h 3.000 t/y dried biomethane sludge PCI mix: 3’120 kJ/kg tq 6240 t/y ashes 4.800 MWh/y el. 27.600 MWh heat (district heating) POSITIVE EFFECT ON SLUDGE DISPOSAL COSTS Mercato estero - hp no agricoltura Mercato esterno - hp 2019 Outsourcing Sludge 2018 - budget realistico Internalization (fluidized bed) Internalizzazione 0 20 40 60 80 100 120 140 2018 - budget Mercato esterno - Mercato estero - hp Internalizzazione realistico hp 2019 no agricoltura CAPEX 53 0 0 OPEX 41 100 109 129 €/ton …and on valorizations costs of OFMSW thanks to the reuse of existing anaerobic digesters and of the existing effluents treatment capacity (-15/20% vs market) POSITIVE EFFECT ON the ENVIRONMENT - LCA A REAL OPPORTUNITY FOR P-RECOVERY – Water Stream ▪ Integrated treatment of sewage and OFMSW: ▪ 40 tonP/y of phosphorus as struvite (compared to 6 tonP/year with only sludges) ▪ The VFA plant (from primary and excess sludge) is under commissioning ▪ 160-180 tCOD/y of organic chemical (VFA) for denitrification/biological phosphorus removal in water line + 110-130 tonCOD/year for supernatant ▪ SCENA plant realization by the end of 2020 -> designed both for sludge and OFMSW supernatant treatment ▪ Still looking for a partner for a struvite demonstration plant… AN OPPORTUNITY FOR P-RECOVERY? – Sludge Stream 62.000 t/year dewatered sludges Drier (24% TS) ASHES Phosphorus + recovery + (6.800 ton/y ) Fluidised bed technologies still 3.000 t/year dried 500 tonP/year? to be assessed sludges (90% TS) reactor VALUE CHAIN STILL TO BE DEFINED Legislation and Raw materials Treatment and extraction other initiatives End use ▪ Need for centralized ▪ STRUBIAS ▪ Is the CAP project «big» enough to ▪ End-users still to be treatment plants ▪ Organic fertilzers ensure profitability? involved in Italy (sludge mono- regulation ▪ Which is the most suitable incineration and technical solution for the CAP case WWTP+OFMSW ▪ Italian Phosphorus still to be developed platform ▪ Which is the best business model? in Italy) ▪ Decentralized P-extraction ▪ Real productivity to plants? be assess trough ▪ One unique regional platform? pilots ▪ Export of ashes? TIME SCHEDULE December 2016 MOU July 2018 Preliminary design and investment approved by Authority December 2018 - Stakeholders engagement GO from municipalities September 2018 - December 2019 Detailed design and permits December 2020 June 2020 Works Tendering Commencement November 2022 – OFMSW date November 2023 - Sludge treatment We believe in Citizens participation http://www.biopiattaformalab.it/ DIGITALIZATION AND EUROPEAN NETWORKING AS ENABLER • Call H2020-SC5-11-2018 «Digital solutions for water: linking the physical and digital world for water solutions» • Project duration: 42 months • Start date: June 2019 • Partnership: 23 + 1 (Coordinator) partners DWC will create new linkages between the digital and the physical world by developing,