Trends and Perspectives in Industrial Water Treatment Raw Water – Process – Waste Water Position Paper by the ProcessNet Subject Division Production-Integrated Water/Waste Water Technology imprint table of contents Table of Contents SUMMARY 2 I TRENDS AND PERSPECTIVES 1 Introduction 4 1.1 Present Situation 5 imprint 1.2 Near Future 8 Authors 2 Vision 2030 9 Dr. Angela Ante SMS SIEMAG Aktiengesellschaft, Hilchenbach 2.1 General Framework 2030 9 Dr.-Ing. Joachim Behrendt TU Hamburg-Harburg 2.2 State of the Art 2030 10 Dr. Helmut Bennemann Bayer Pharma AG, Bergkamen Dr. Christoph Blöcher Currenta GmbH & Co. OHG, Leverkusen 3 Fields of Action and R&D Needs 11 Dipl.-Ing. Peter Bolduan atech innovations gmbh, Gladbeck 3.1 Smart water management 11 Prof. Dr.-Ing. Sven-Uwe Geißen TU Berlin 3.2 Water: quantity, quality, resources 12 Prof. Dr. Harald Horn Karlsruher Institut für Technologie – KIT 3.3 Waste water: networks, treatment plant, receiving water, waste water levy 12 Prof. Dr. Rainer Krull TU Braunschweig 3.4 Pollutants, hygiene: substances, concentrations, limit values 13 Prof. Dr. Peter M. Kunz Hochschule Mannheim Prof. Dr. Joachim M. Marzinkowski Bergische Universität Wuppertal 3.5 Water-energy nexus 13 Dr. Stefan Neumann LANXESS Deutschland GmbH, Leverkusen 3.6 Technology: integration, efficiency enhancement, transfer 13 Dr. Volker Oles EnviroChemie GmbH, Roßdorf 3.7 Recovery: raw materials, valuables, energy 14 Dr. Hans-Werner Rösler Innovest Beteiligungs GmbH, Wuppertal 3.8 Footprint: CO2, virtual water, LCA 15 Dr.-Ing. Elmar Rother Evonik Industries AG, Hanau 3.9 Change of industrial productionn 15 Prof. Dr. Karl-Werner Schramm Helmholtz Zentrum München 3.10 Environment: climate, residues 15 Prof. Dr.-Ing. Michael Sievers CUTEC-Institut GmbH, Clausthal-Zellerfeld 3.11 Salts: regional/global, medial shift, reduction, salt utilization 16 Prof. Dr. Ulrich Szewzyk TU Berlin 3.12 Socio-economic environment 16 Dr. Thomas Track DECHEMA e.V., Frankfurt/Main 3.13 Responsibility for the future: holistic approach, consequences of an optimized water management 16 Dr. Ingolf Voigt Fraunhofer- Institut für Keramische Technologien und Systeme – IKTS, Hermsdorf 3.14 Qualification and public relations 17 Dipl.-Ing. Hubert Wienands Wehrle-Umwelt GmbH, Emmendingen II ROUTES TO REALIZATION Edditor 4 Cross-technology Approaches 18 ProcessNet Subject Division “Production-Integrated Water and Waste Water Technology“ 4.1 Production-integrated Measures for an Energy-efficient Water Recycling 18 4.2 Recovery of Valuable Substances 21 Responsible according to the German Press Law 4.3 Salts 26 DECHEMA e.V. Dr. Andreas Förster 5 Processes for Realization 29 Theodor-Heuss-Allee 25 5.1 Biological Processes 29 60486 Frankfurt am Main 5.1.1 General 29 5.1.2 Anaerobic Processes 33 Published in May 2017 5.1.3 Aerobic Membrane Bioreactors 34 5.2 Advanced Oxidation Processes (AOP) 37 ISBN: 978-3-89746-194-9 5.3 Membranes for Water and Waste Water Treatment 38 © Photo collage, front page: photo segments f.l. © Project Photos, EnviroChemie GmbH, Christoph Fein/Essen 2006 1 summary summary Summary Water is vital for the industry sector, both at the national With a view to the state of the art in the year 2030 the fol- Fourteen fields of action with the corresponding R&D These fields of action and the resulting development and at the international level. The water technology needs lowing R&D targets for an integrated, sustainable indus- needs can be derived from the Vision 2030: needs in turn lead to R&D focuses for cross-technology of the industry sector do not only differ fundamentally trial water management can be defined: approaches and processes that must be addressed al- 1. Smart water management from those of the municipal sector, they also vary strong- ready today so as to be able to achieve an integrated, sus- ly between industries and locations so that standardized » Smart management systems control the distribution 2. Water: quantity, quality, resources tainable industrial water management by the year 2030: solutions are not feasible. Rather, the different needs call and utilization of water with due consideration of the 3. Waste water: networks, sewage treatment plant, for a combination of methodical/technical know-how and technical/natural water networks and cycles (smart receiving water, waste water levy » Production-integrated measures targeting an customized process technology. In view of the close inter- networks). Waste water is routed to municipal waste energy-efficient water recycling action between production and water technology, integra- water treatment plants and surface waters taking into 4. Pollutants, hygiene: substances, concentrations, limit values tive technologies and management systems are called for. account the performance capacity of the infrastructure » Recovery of valuables in place with the aim of avoiding damage to natural 5. Water-energy nexus The resulting integrated, sustainable industrial water water bodies and shifts into other environmental com- » Handling of salts 6. Technology: integration, efficiency enhancement, management curbs the dependency of production pro- partments. These premises also apply for the emission transfer cesses from external water, raw materials and energy of heat. » Biological processes sources and from other influencing factors such as the 7. Recovery: raw materials, valuables, energy regulatory framework. It is not only relevant for the Ger- » The continuous optimization of production systems by » Advanced oxidation processes 8. Footprint: CO2, virtual water, life cycle assessment man market, but also boosts the export of technologies, production-integrated processes results in a progres- (LCA) equipment, engineering and other services and enhances sive reduction of water demand and pollution loads » Membranes for water and waste water treatment the competitiveness of German companies in the interna- and enhances the economic efficiency of recycling pro- 9. Change of industrial production tional markets. cess water, valuable substances and process heat. At 10. Environment: climate, residues In this position paper, the present situation for these ap- the same time, demands on water quality are increas- proaches/processes is described, their application poten- 11. Salts: regional/global, medial shift, reduction, In view of the high innovation potential of an integrated, ing. Investment decisions are taken on the basis of the tials characterized, the specific research and development salt utilization sustainable industrial water management, the ProcessNet Life Cycle Assessment (LCA), Life Cycle Costing (LCC) needs are derived, and the anticipated impact of their re- Subject Division “Production-Integrated Water and Waste and other tools to evaluate sustainability. 12. Socioeconomic environment alization is assessed. Water Technology“ set itself the task of presenting the 13. Responsibility for the future: holistic approach, trends and perspectives in industrial water treatment. » The substances contained in industrial waste wa- consequences of an optimized water management ter and waste water partial flows are largely known. Using the present situation as a basis, a vision for the sit- Transformation products resulting from biological/ 14. Qualification and public relations uation in the year 2030 is derived from the (mega) trends chemical degradation processes as well as the release and the R&D targets, challenges and resulting fields of of substances by water treatment processes are large- action are defined. In a next step, the research and de- ly avoided or almost completely biodegradable (min- velopment needs to realize this vision are described and eralizable). potential routes to realization are presented (Fig. I). Vision 2030 Fields of Action Implementation • Consideration of the • Definition of the • Deriving the R&D Integrated, (mega) trends and global challenges and fields needs sustainable industrial framework of action • Routes to realization water management • State of the art • Requirements/ R&D targets Fig. I: The route towards an integrated, sustainable industrial water management 2 3 i trends und perspektives i trends und perspektives vision has set itself the task of presenting the trends and period under review – also systemic solution approaches. I Trends und Perspektives perspectives in industrial water technology. The present With the year 2030, a manageable period of time has been paper is primarily based on the situation in Germany, but defined that is sufficiently large for developing systemic also takes into account the fact that industrial production concepts. in the same way as the water technology are embedded in 1 Introduction an international context. Based on the present situation, a From the vision for the year 2030, the challenges and the vision for the situation in the year 2030 is derived from the corresponding fields of action are derived. To achieve the Water is vital for industry, both at the national and at the The ProcessNet Subject Division “Production-integrated (mega) trends and development targets are defined. Al- defined development targets, the research and develop- international level. The water technology of the industri- Water and Waste Water Technology” examines the state- though forecasts always involve elements of uncertainty, ment needs for the implementation are described and po- al sector differs fundamentally from that of the municipal of-the-art of science and technology and new perspec- they encourage discussions and open up