Hydrothermal Carbonization of Sludge Including Recycling of a Wet-Oxidized Fraction

Abstract

There is provided a method of hydrothermal carbonization of a sludge, comprising the steps of: preheating the sludge to obtain a preheated sludge; mixing the preheated sludge with a wet-oxidized fraction to obtain a reaction mixture; subjecting the reaction mixture to hydrothermal carbonization (HTC) in a reactor to obtain a HTC-treated sludge; separating a fraction from the HTC-treated sludge; and mixing the fraction with an oxidizing agent, such as oxygen gas, to obtain the wet-oxidized fraction, wherein the temperature of the fraction before the wet oxidation is at least 15 C. higher than the temperature of the preheated sludge. A corresponding system is also provided.

Claims

1. A method of hydrothermal carbonization of a sludge, comprising the steps of: preheating the sludge to obtain a preheated sludge; mixing the preheated sludge with a wet-oxidized fraction to obtain a reaction mixture; subjecting the reaction mixture to hydrothermal carbonization (HTC) in a reactor to obtain a HTC-treated sludge; separating a fraction from the HTC-treated sludge; and mixing the fraction with an oxidizing agent to obtain the wet-oxidized fraction, wherein the temperature of the fraction before the wet oxidation is at least 15 C. higher than the temperature of the preheated sludge.

2. The method according to claim 1, wherein the total suspended solids (TSS) content of the fraction is lower than the TSS content of the HTC treated sludge.

3. The method according to claim 1, wherein the TSS content of the fraction is lower than 50 g/l.

4. The method according to claim 1, further comprising obtaining a second fraction from the HTC-treated sludge and subjecting the second fraction to flashing to obtain at least one steam fraction and a cooled fraction, wherein the at least one steam fraction is used in the preheating step.

5. The method according to claim 4, wherein the total suspended solids (TSS) content of the second fraction is higher than the TSS content of the fraction that is mixed with the oxidizing agent.

6. The method according to claim 1, wherein the sludge is a municipal or industrial sludge from a wastewater treatment plant.

7. The method according to claim 1, wherein the temperature of the HTC-treated sludge is 180-250 C.

8. The method according to claim 1, wherein the temperature of the HTC-treated sludge is at least 20 C. higher than the temperature of the preheated sludge that is mixed with the wet-oxidized fraction.

9. The method according to claim 1, wherein the average retention time in the reactor is 0.25-8 h.

10. The method according to claim 1, wherein the volumetric flow rate of the fraction is 10-50% of the volumetric flow rate of the preheated sludge.

11. The method according to claim 1, wherein the chemical oxygen demand (COD) of the fraction is at least 15 g/l.

12. The method according to claim 1, wherein preheated sludge is mixed with the wet-oxidized fraction in the reactor.

13. The method according to claim 1, wherein preheated sludge is mixed with the wet-oxidized fraction in a position upstream the reactor.

14. The method according to claim 1, wherein the temperature of the fraction before the wet oxidation is at least 20 C. higher than the temperature of the preheated sludge.

15. The method according to claim 1, wherein the amount of oxidizing agent is such that wet oxidation reactions reduces the higher heating value (HHV) of the sludge by 5-49%.

16. A system for hydrothermal carbonization of a sludge, comprising: an inlet for receiving sludge; a reactor for subjecting sludge to a hydrothermal carbonization (HTC) such that HTC-treated sludge is obtained; a routing arrangement for routing sludge from the inlet to the reactor, which arrangement comprises a preheating arrangement; and a recirculation arrangement for routing a first fraction of the HTC-treated sludge to a position on the first routing arrangement between the preheating arrangement and the reactor or to the reactor, which recirculation arrangement comprises a mixer for mixing the first fraction with an oxidizing agent.

17. The system according to claim 16, wherein the oxidizing agent is oxygen gas and the mixer is an oxygen gas mixer.

18. The system according to claim 16, further comprising: a flashing arrangement for subjecting a second fraction of HTC-treated sludge to flashing to obtain a cooled second fraction and at least one steam fraction; and a steam routing arrangement for routing the at least one steam fraction to the preheating arrangement.

19. The system according to claim 18, wherein the reactor comprises a first outlet for the first fraction and a second outlet for the second fraction, wherein the first outlet is arranged above the second outlet.

20. The method of claim 1, wherein the oxidizing agent is oxygen gas.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0065] FIGS. 1a, 1b, 2a and 2b illustrate different exemplary embodiments of a system for sludge treatment according to the present disclosure.

DETAILED DESCRIPTION

[0066] A first exemplary embodiment of a system 100 according to the present disclosure is schematically illustrated in FIG. 1a. For the process in the system, a sludge is received (A) from a source, which can be a municipal wastewater treatment plant, an industrial process, or an installation in agriculture or animal farming. The sludge may be received directly from the plant or from a storage tank that forms part of the system. The sludge typically has an initial temperature of about 30 C. and a dry matter content of about 30%. After optional initial heating (not shown), e.g. by a liquid stream from the same process/system, the sludge is preheated in a preheating arrangement 101. The preheating is preferably carried out by stepwise additions of steam, e.g. in a first 102, a second 103 and a third 104 steam mixer arranged in series. Downstream each steam mixer 102, 103, 104, a pump 102p, 103p, 104p is arranged. The last pump brings the pressure up to the pressure of the HTC reaction discussed below. After the preheating arrangement 101, a preheated sludge having a temperature of about 175 C. is obtained. In a T-type connection 105 (or a more advanced device for mixing two flows), the preheated sludge is merged with a wet-oxidized fraction to form a reaction mixture, which is fed to a vertical reactor 106, preferably through an inlet 107 arranged at the bottom of the reactor 106. In the reactor 106, the reaction mixture undergoes hydrothermal carbonization (HTC). The temperature of the sludge may vary between different positions in the reactor 106 because of exothermic reactions (e.g. the HTC reactions and the wet oxidation discussed below) and heat losses. A HTC treated sludge is withdrawn from the reactor 106, preferably through an outlet 108 arranged at a top section of the reactor 106. The temperature of the heat treated sludge is 200-215 C. when it is withdrawn from the reactor 106.

[0067] A fraction is separated 109 from the HTC-treated sludge. The pressure of the fraction is increased slightly by a pump no. Oxygen gas is then added to the fraction in an oxygen gas mixer in such that the wet-oxidized fraction is obtained. The oxygen gas mixer is connected to an oxygen tank (not shown). The amount of oxygen gas may be about 130 kg per tonne of dry sludge processed in the system. The wet oxidation is not instantaneous. Rather, it will be ongoing when the fraction flows downstream the oxygen gas mixer 111 and possibly also after the merge with the preheated sludge.

[0068] The volumetric flow rate of the fraction is 10-50% of the volumetric flow rate of the preheated sludge.

[0069] The remaining HTC-treated sludge forms a second fraction that instead of being recirculated is subjected to flashing in a flashing arrangement 112, which produces at least one steam fraction that is used to preheat the sludge in the preheating arrangement 101. Preferably, the flashing arrangement 112 comprises several flashing vessels arranged in series to produce steam fractions of different temperatures. For example, the flashing arrangement 112 may comprise: a first flashing vessel 113 that produces a steam fraction of relatively high temperature that is routed to the third steam mixer 104 of the preheating arrangement 101; a second flashing vessel 114 that produces a steam fraction of medium temperature that is routed to the second steam mixer 103 of the preheating arrangement 101; and a third flashing vessel 115 that produces a steam fraction of relatively low temperature that is routed to the first steam mixer 102 of the preheating arrangement 101.

[0070] The cooled slurry obtained downstream the flashing arrangement 112 is dewatered (not shown) such that at least one liquid stream (that can be used for initial heating and/or dilution of incoming sludge) and a thick fraction comprising HTC coal are obtained.

[0071] The system 100 may comprise a heater 116 using external heat, such as an electrical heater, for cold starting the process. The heater 116 is preferably arranged downstream the merging point 105, but upstream the reactor 106.

[0072] A variant of the first exemplary embodiment is illustrated in FIG. 1b. The difference between FIG. 1b and FIG. 1a is that the wet-oxidized fraction is not merged with the preheated sludge in a position upstream the reactor 106. In FIG. 1b, the wet-oxidized fraction and the preheated sludge are instead separately added to an upstream portion of the reactor 106 and thus mixed in the reactor 106 to form the reaction mixture.

[0073] A second exemplary embodiment of a system 200 according to the present disclosure is schematically illustrated in FIG. 2a. For the process in the system 200, a sludge is received (A) from a source, which can be a municipal wastewater treatment plant, an industrial process, or an installation in agriculture or animal farming. The sludge may be received directly from the plant or from a storage tank that forms part of the system. The sludge typically has an initial temperature of about 30 C. and a dry matter content of about 30%. After optional initial heating (not shown), e.g. by a liquid stream from the same process/system, the sludge is preheated in a preheating arrangement 201. The preheating is preferably carried out by stepwise additions of steam, e.g. in a first 202, a second 203 and a third 204 steam mixer arranged in series. Downstream each steam mixer 202, 203, 204, a pump 2o2p, 2o3p, 2o4p is arranged. The last pump brings the pressure up to the pressure of the HTC reaction discussed below. After the preheating arrangement 201, a preheated sludge having a temperature of about 175 C. is obtained. In a T-type connection 205 (or a more advanced device for mixing two flows), the preheated sludge is merged with a wet-oxidized fraction to form a reaction mixture, which is fed to a vertical reactor 206, in which the reaction mixture is subjected to hydrothermal carbonization (HTC) and the HTC-treated sludge is separated into a particle-lean fraction and a particle-rich fraction. The reactor 206 comprises: a reactor inlet 207 arranged at the top of the reactor 206; a first channel 206c1 extending downwardly from the reactor inlet 207 for guiding the reaction mixture from the inlet 207 to a bottom section of the reactor 206; a second channel 206c2 extending upwardly from the bottom section to a recirculation outlet 208 for withdrawing the particle-lean fraction; and a lower outlet 209 for withdrawing the particle-rich fraction. The design of the reactor 206 enables fluidization that facilitates the separation into the particle-lean fraction and the particle-rich fraction (see patent application SE 1750284 A1).

[0074] Preferably, part of the particle-lean stream is recirculated to a bottom inlet 207b of the reactor 206. A flow through such a bottom inlet aids the fluidization.

[0075] Oxygen gas is added to the other part of the particle-lean fraction or to all of it in case the recirculation to the bottom inlet is omitted. By the oxygen addition, the wet-oxidized fraction is obtained. The addition is made by means of an oxygen gas mixer 211, which is connected to an oxygen tank (not shown). The amount of oxygen gas may be about 130 kg per tonne of dry sludge processed in the system. The wet oxidation is not instantaneous. Rather, it will be ongoing when the fraction flows downstream the oxygen gas mixer 211 and possibly also after the merge with the preheated sludge. Before the oxygen gas mixer 211, the pressure of the particle-lean fraction is increased slightly by a pump 210.

[0076] The volumetric flow rate of the wet-oxidized fraction is 10-50% of the volumetric flow rate of the preheated sludge.

[0077] The temperature varies slightly between different positions in the reactor 206 because of exothermic reactions (e.g. the HTC reactions and the wet oxidation) and heat losses. The particle-lean fraction and the particle-rich fraction have a temperature within the range of 200-215 C. when they are withdrawn from the reactor 206.

[0078] The particle-rich fraction is subjected to flashing in a flashing arrangement 212, which produces at least one steam fraction that is used to preheat the sludge in the preheating arrangement 201. Preferably, the flashing arrangement 212 comprises several flashing vessels arranged in series to produce steam fractions of different temperatures. For example, the flashing arrangement 212 may comprise: a first flashing vessel 213 that produces a steam fraction of relatively high temperature that is routed to the third steam mixer 204 of the preheating arrangement 201; a second flashing vessel 214 that produces a steam fraction of medium temperature that is routed to the second steam mixer 203 of the preheating arrangement 201; and a third flashing vessel 215 that produces a steam fraction of relatively low temperature that is routed to the first steam mixer 202 of the preheating arrangement 201.

[0079] The cooled slurry obtained downstream the flashing arrangement 212 is dewatered (not shown) such that at least one liquid stream (that can be used for initial heating and/or dilution of incoming sludge) and a thick fraction comprising HTC coal are obtained.

[0080] The system 200 may comprise a heater 216 using external heat, such as an electrical heater, for cold starting the process. The heater 216 is preferably arranged downstream the merging point 205, but upstream the reactor 206.

[0081] A variant of the second exemplary embodiment is illustrated in FIG. 2b. The difference between FIG. 2b and FIG. 2a is that the wet-oxidized fraction is not merged with the preheated sludge in a position upstream the reactor 206. In FIG. 1b, the wet-oxidized fraction and the preheated sludge are instead separately added to an upstream portion of the reactor 206 and thus mixed in the reactor 206 to form the reaction mixture.