SE540136C2 - Continuous vertical reactor and system and method for sludget treatment - Google Patents

Abstract

There is provided a continuous vertical reactor (404) designed to treat pressurized aqueous sludge having a temperature of at least 150 °C, which reactor (404) comprises a reactor top inlet (408) arranged at a top section (405) of the reactor (404), wherein:a first channel (401) extends downwardly from the reactor top inlet (408) for guiding sludge from the reactor top inlet (408) to a bottom section (406) of the reactor (404);a second channel (402) extends upwardly from the bottom section (406); at least one separation wall (403), which preferably is essentially vertical, separates first channel (401) from the second channel (402); andan opening (407) through which sludge may flow from the first channel (401) into the second channel (402) is provided at the bottom section (406) of the reactor (404),wherein the reactor (404) further comprises:at least one upper outlet (412) arranged at the second channel (402) to connect to a recirculation conduit (409) for recirculation of a fraction of the heat-treated sludge; andat least one lower outlet (413) that can be connected to an arrangement for cooling heat-treated sludge, which at least one lower outlet (413) is/are arranged below the at least one upper outlet (412).

Description

CONTINUOUS VERTICAL REACTOR AND SYSTEM AND METHODFOR SLUDGE TREATMENT TECHNICAL FIELD The present disclosure relates to the field of sludge treatment and inparticular to a continuous vertical reactor designed to treat pressurized aqueous sludge having a temperature of at least 150 °C.

BACKGROUND Sludge is what remains after Wastewater treatment in municipal andindustrial treatment plants. Municipal plants treat Wastewater from citieswhile industrial wastewater treatment plants treat water effluents from e.g.pulp and paper mills etc. The wastewater treatment process technologies areprincipally the same but include specific solutions depending on e.g. influentto be treated, basic design, local prerequisites and environmental concerns.In larger plants in Sweden, the wastewater treatment process often comprisesmechanical pretreatment followed by primary (settling) and secondary(aerobic) treatment steps. In some cases tertiary treatment is also applied toremove remaining problematic substances in treated water. In smaller plants one or more of these stages is/ are often omitted.

All plants in use generate sludge that needs to be handled. The sludge iseither taken out directly from the plant after dewatering (aerobic sludge) orfirst treated anaerobically for biogas production where part of the sludge is digested and the remainder is taken out as anaerobic sludge.

The exact composition of the sludge depends on the composition of thewastewater influent and the type of wastewater treatment plant. Sludge withhigh concentrations of organic and/ or biological components is generallydifficult to dewater. The water content is so high that net heating value ifincinerated in a power plant is very low or even negative. Additionalproblems are various contaminants and pathogens, which limits the usability of the sludge in other applications.

There are several options for sludge handling today, depending on national legislation. Sludge can be landfilled, either directly or after anaerobictreatment. Agricultural applications are common where the sludge is used asfertilizer on farmland either directly or after composting where the sludge ishygienized. Incineration of the sludge is in use in several countries either directly or after drying.

The current sludge handling is costly (up to 50% of the total operating costsfor a municipal Wastewater treatment plant), requires large surface areas forsludge composting and hygienization and does not utilise the energy value ofthe sludge since it is too wet to combust efficiently without previous energy-intensive drying. It has a negative impact on the environment due totransports of large volumes of water, land-use, risks for heavy metal and organic toxin release and emissions of the strong greenhouse gas methane.

From 196o”s and onwards, the Porteous process and other similar processesfor heat-treating sludge to improve dewatering properties underhydrothermal carbonization conditions have been developed. Other methods,i.e. Veolia”s “Exelys” and the Cambi process utilise heat treatment beforeanaerobic treatment of the sludge to improve the biogas yield. Theseprocesses use lower temperatures than in hydrothermal carbonization. Thereare also other heat treatment methods that utilise sub-critical and super-critical (SCWO) processes.

SUMMARY The present inventors have realized that handling of the sludge fromwastewater treatment plants have been inefficient, costly andenvironmentally questionable. For example, sludge from Swedish municipalwastewater treatment plants have been transported to northern Sweden anddumped into abandoned underground mines. Due to the high water contentof the sludge, the costs and environmental impact of such handling areextensive. Further, the sludge from waste water treatment plants (includingaerobic and anaerobic sludge) often contains pathogens and problematicmetals and can possess pharmaceutical activity, which poses restrictions towards utilization in agriculture and soil-improvement applications.

The present inventors have noted that the prior art processes for heat-treatment of the sludge were associated with a number of significantproblems, such as technology for heating, plugging of heat exchangers,corrosion and return of refractory organic substances to the Wastewatertreatment plant. For example, most of the earlier Porteous processes wereclosed down due to technical and economical reasons. The technical solutionsand material selections were not optimal under the conditions prevailing atthat time. Further, the prior art heat-treatment processes were carried out in large plants built within the wastewater treatment plants.

In the prior art methods based on sub-critical and super-critical (SCWO)conditions, oxygen is added to destroy the organic material, which results inthat the heat value cannot be recovered in solid fuel. Oxygen can be suppliedeither from a dedicated oxygen plant or via air; both procedures add however capital and operating costs.

It is thus an object of the present disclosure to improve the handling of sludge from sewage treatment plants.

To facilitate such improved handling, the present disclosure provides aninventive reactor defined by the appended claims. The claimed reactor is also described below under Examples with reference to figure 4.

The present disclosure is further based on a number of insights. Firstly, theinventors have found that the sludge can be further treated with a processcomprising heating, not only to reduce the need for transport, but also tohygienize the sludge, reduce the activity of problematic compounds andprovide valuable products, such as a fuel and a product having fertilizervalue. Secondly, the inventors have realized that instead of adding furtherequipment inside the sewage treatment plant, the equipment for such furthertreatment of the sludge can, if designed properly, be arranged in atransportable container. The installation of the equipment can thus avoidcivil costs and be standardized, which significantly reduces the cost compared to a customized installation inside the plant. Transport of the equipment to the sewage treatment site is also highly efficient when it is arranged in acontainer that is adapted to be loaded on and off a truck. Thirdly, theinventors have realized that once the format of a container has been selected,certain adaptations need to be made. For example, steam, which is normallyconsidered to be the most economical heat source in industrial processes, isnormally not available at a Wastewater treatment site and often it is notpractical to install a steam boiler, feedwater treatment system and a fuelsystem in the container. Therefore, electrical heating is preferred for capitaland safety reasons when the heat treatment is carried out in a transportable container.

The following itemized listing of non-claimed embodiments of the present disclosure is thus provided. 1. A system for sludge treatment, which system is arranged in a container and comprises:a sludge inlet for receiving a sludge; a reactor comprising an electrical heating arrangement for heat treatment of the sludge, which reactor is arranged downstream the sludge inlet; a flashing arrangement for cooling sludge treated in the reactor andproviding at least one steam fraction, which flashing arrangement is arranged downstream the reactor; a steam routing arrangement capable of routing the at least one steamfraction from the flashing arrangement to preheat sludge transported from the sludge inlet to the reactor; and a separation arrangement for separating the cooled sludge from theflashing arrangement into a first fraction and a second fraction, wherein thesuspended solids content is higher in the first fraction than in the second fraction. 2. The system according to item 1, wherein the reactor comprises at leastone outlet connected to the flashing arrangement and at least onerecirculation conduit on which the electrical heating arrangement is arranged. 3. The system according to item 2, wherein the reactor is adapted toprovide an outlet fraction for leaving the reactor through the at least oneoutlet connected to the flashing arrangement and a recirculation fraction forrecirculation in the recirculation conduit and wherein the average particle size is larger in the outlet fraction than in the recirculation fraction. 4. The system according to item 3, wherein the reactor is vertical and anoutlet for the recirculation conduit is arranged above the at least one outlet connected to the flashing arrangement.5. The system according to item 4, wherein the reactor comprises:a reactor inlet arranged at the top of the reactor; a first channel extending downwardly from the reactor inlet for guiding sludge from the inlet to a bottom section of the reactor; and a second channel extending upwardly from the bottom section to the outletfor the recirculation conduit, which second channel is separated from the first channel by at least one wall. 6. The system according to any one of the preceding items, wherein theflashing arrangement comprises a least one flash tank, each flash tank comprising a steam outlet connected to the steam routing arrangement. 7. The system according to item 6, wherein the flashing arrangementcomprises at least two flash tanks arranged in series to provide steam fractions of different pressures. 8. The system according to item 7, wherein the flashing arrangementcomprises at least three flash tanks arranged in series to provide steam fractions of different pressures. 9. The system according to any one of the preceding items, wherein theseparation arrangement comprises a settling arrangement, such as a settlingtank, for separating the cooled sludge from the flashing arrangement into aclear fraction and a sediment fraction, which settling arrangement is arranged downstream the flashing arrangement. 10. The system according to item 9, wherein the separation arrangementfurther comprises a filter, such as a membrane, arranged downstream thesettling arrangement for separating the clear fraction into a filtrate and a retentate. 11. The system according to item 10, further comprising a conduit forrecirculating the retentate to the sludge transported from the sludge inlet to the reactor. 12. The system according to item 10 or 11, further comprising a heatexchanger arranged to transfer heat from the filtrate to the sludge from the sludge inlet. 13. The system according to anyone of items 9-12, further comprising asediment separation unit, such as a filter press, arranged downstream thesettling arrangement for separating the sediment fraction into a solids fraction and a liquid fraction. 14. The system according to item 13, further comprising a conduit formerging at least part of the liquid fraction from the sediment separation unit with the clear fraction from the settling arrangement. 15. The system according to item 14 in combination with any one of items9-11, wherein the liquid fraction from the sediment separation unit and the clear fraction from the settling arrangement are merged upstream the filter. 16. The system according to anyone of items 13-15, further comprising aconduit for merging at least part of the liquid fraction from the sediment separation unit with the sediment fraction from the settling arrangement. 17. The system according to any one of the preceding items, furthercomprising a phosphorous separation unit for separating phosphorous from the first fraction, the sediment fraction or the solids fraction. 18. A method of sludge treatment, which method is carried out in a container and comprises: preheating a sludge with at least one steam fraction to obtain a preheated sludge; further heating the preheated sludge to temperature of 150-250 °C using electrical heating to obtain a heat-treated sludge; flash cooling the heat-treated sludge to obtain the at least one steam fraction used for the preheating and a cooled sludge; separating the cooled sludge into a first fraction and a second fraction,wherein the suspended solids content is higher in the first fraction than in the second fraction. 19. The method of item 18, wherein the preheated sludge is heated to a temperature of 150-220 °C, 170-250 °C or 170-240 °C. 20. The method of item 18 or 19, wherein the preheated sludge is furtherheated in a reactor in which the sludge is separated into a recirculationfraction that is recirculated to the reactor and an outlet fraction that issubjected to said flash cooling and wherein the average particle size is larger in the outlet fraction than in the recirculation fraction. 21. The method of item 20, wherein the separation is involves fluidization or sedimentation of particles in the reactor. 22. The method of item 21, wherein the reactor is a vertical reactor and thesludge is fed to an inlet at the top of the reactor and guided downwardlythrough a first channel in the reactor and then upwardly through a secondchannel in the reactor and wherein the recirculation fraction is withdrawnfrom the reactor at a position that is located higher up in the second channel than a position at which the outlet fraction is withdrawn. 23. The method of any one of items 18-22, wherein at least two, such as atleast three steam fractions of different temperatures are obtained in the flashcooling and used sequentially in the preheating such that the sludge is first preheated with the steam fraction of the lowest temperature. 24. The method of any one of items 18-23, wherein the separation of thecooled sludge involves settling to obtain a clear fraction and a sediment fraction. 25. The method according to item 24, wherein the clear fraction is subjected to filtering, such as membrane filtering, to obtain a filtrate and a retentate. 26. The method according to item 25, wherein the retentate is recirculated such that it is combined with the sludge and heat-treated. 27. The method according to item 25 or 26, wherein heat is exchanged between the filtrate and the sludge upstream of the preheating. 28. The method according to any one of items 24-27, wherein the sedimentfraction is separated into a solids fraction and a liquid fraction, preferably by means of a filter press. 29. The method according to item 28, further comprising merging at least part of the liquid fraction with the clear fraction from the settling. 30. The method according to item 29, further wherein the at least part of the liquid fraction and the clear fraction are merged upstream the filtering. 31. The method according to anyone of items 28-30, wherein at least part of the liquid fraction is merged with the sediment fraction. 32. The method according to any one of items 18-31, further comprisingseparation of phosphorus from the first fraction, the sediment fraction or the solids fraction.

BRIEF DESCRIPTION OF THE DRAWINGS Fig 1 is a simplified scheme of an embodiment of a container according to the present disclosure comprising a flashing arrangement and a settling tank.

Fig 2 is a simplified scheme of another embodiment of a container accordingto the present disclosure comprising an arrangement for indirect heat exchange and a settling tank.

Fig 3 is a simplified scheme of another embodiment of a container accordingto the present disclosure comprising a flashing arrangement and a separation arrangement without a settling tank.

Fig 4 illustrates an embodiment of a vertical reactor according to the present invention for heat treatment of sludge.

DETAILED DESCRIPTION The reactor of the present invention is a continuous vertical reactor designedto treat pressurized aqueous sludge having a temperature of at least 150 °C.The reactor is further described under Examples below with reference to figure 4.

The sludge of the present disclosure may be obtained from municipal orindustrial wastewater treatment plants. Accordingly, the sludge of the presentdisclosure may be municipal sludge or industrial sludge. Further, the sludge of the present disclosure may be anaerobic sludge or aerobic sludge.

The dry solids content (also referred to as “Total Solids”) of the sludge istypically 1-35 %, such as 2-35 %, such as 3-32 %. If the sludge is anaerobic sludge, the dry solids content is normally 13-32 %. If the sludge is aerobic sludge, the dry solids content is typically 5-15 %. The ash content is typically15-75 %, such as 30-50 %, of the dry weight of the sludge. The higher heatingvalue (HHV) of the sludge is typically 35-21 MJ /kg, such as 6-17 MJ /kg (dryweight).

The sludge composition can vary to a great degree depending on theincoming Wastewater and the treatment methods applied. Industrial sludge,e.g. from the pulp and paper industry, can have compositions that differ frommunicipal sludge. Further, the driving forces for treatment of the sludge canbe different for industrial sludges. For example, phosphorous recovery can be less interesting in case of industrial sludge.

One interesting embodiment relates to phosphorus in the sludge as thepresent disclosure facilitates the separation thereof. Therefore, the sludge ofthe present disclosure preferably comprises phosphorus (P), e.g. in anamount of 0.5-9 % of the dry weight of the sludge, such as 1-9 % of the dryweight of the sludge, such as 1.5-9 % of the dry weight of the sludge.

Further, the treated sludge can be used as a fuel. Therefore, the sludge of thepresent disclosure preferably comprises carbon (C), e.g. in an amount of 9-46% of the dry weight of the sludge, such as 20-46 % of the dry weight of thesludge.

The inventive reactor may be part of a system for sludge treatment describedbelow as a first aspect of the present disclosure. The system of the first aspectis arranged in at least one container. Preferably, the system is arranged in a single container.

The container of the present disclosure is preferably adapted to betransported by a truck. The container may be an optionally modifiedintermodal container (also known as an ISO container), which is astandardized reusable steel box. Intermodal containers are normally used tostore and move materials and products efficiently and securely in the globalcontainerized intermodal freight transport system. "Intermodal" indicates that the container can be used across various modes of transport, (from ship 11 to rail to truck) without unloading and reloading its contents. Lengths ofintermodal containers, which each have a unique ISO 6346 reporting mark,vary from 8 to 56 feet (2438 to 17.069 m), whereas heights vary from 8 feet(2438 m) to 9 feet 6 inches (2896 m). Atypical width is 8 feet (2438 m).

The smallest containers normally do not provide enough space for the systemof the first aspect. Accordingly, the length of the container of the presentdisclosure is preferably 5-18 m, such as 6-18 m, such as 9-18 m. The normalheight and width can be used. Accordingly, the height of the container of thepresent disclosure may be 2-3 m, such as 2.4-2.9 m. Further, the width of the container of the present disclosure may be 2-3 m, such as 2.2-2.7 m.

The system comprises a sludge inlet for receiving sludge. A conduit may bearranged to conduct sludge from the sludge inlet to a silo arranged in the container for collecting sludge.

The system further comprises a reactor for heat treatment of the sludge,which reactor is arranged downstream the sludge inlet. If the silo is included,the reactor is also arranged downstream the silo. The reactor preferablycomprises an electrical heating arrangement. However, it is also possible toheat the sludge in another way, such as with steam from a boiler or an eXtelTlal Steam SOIlTCC.

The system further comprises an arrangement for cooling sludge treated in the reactor, which arrangement is arranged downstream the reactor.

In an embodiment, the arrangement for cooling is a flashing arrangement forcooling sludge treated in the reactor and providing at least one steamfraction. In such case, the system further comprises a steam routingarrangement capable of routing the at least one steam fraction from theflashing arrangement to preheat sludge transported from the sludge inlet to the reactor.

The flashing arrangement can for example comprise at least one flash tank, such as at least two flash tanks, such as at least three flash tanks. Each flash 12 tank normally comprises a steam outlet connected to the steam routing arrangement.

In case of at least two flash tanks, the flash tanks may be arranged in series.Accordingly, they may be arranged to provide steam fractions of different pressures.

As understood from the discussion above, the system may comprise a conduitfor conducting sludge from the sludge inlet or the silo to the reactor.Accordingly, at least one pump may be arranged on the conduit. Further, a heat exchanger for preheating the sludge may be arranged on the conduit.

The conduit preferably comprises at least one steam mixer by means of whichthe at least one steam fraction is mixed into the sludge. If the above-mentioned heat exchanger is included, the at least one steam mixer is / arearranged downstream the heat exchanger. The at least one steam mixer mayfor example be at least one venturi steam mixer or at least one mechanical re-compressor with steam nozzle mixer. The former alternative is considered to be more easily implemented in the system.

In another embodiment, the arrangement for cooling sludge treated in thereactor is an arrangement for indirect heat exchange in which heat istransferred from the heat-treated sludge fraction to the sludge without directcontact. Such an arrangement for indirect heat exchange may comprise aseries of indirect heat exchangers, such as two, three or four indirect heatexchangers arranged in series. Examples of indirect heat exchangers are tubular heat exchangers and plate heat exchangers.

The system further comprises a separation arrangement for separating thecooled sludge from the arrangement for cooling into a first fraction and asecond fraction, wherein the suspended solids content is higher in the first fraction than in the second fraction.

The separation arrangement may for example comprise a settling arrangement, such as a settling tank and/ or a solid/ liquid separation unit, 13 such as a filter press. In addition, the separation arrangement may comprisea membrane filter arranged downstream the settling tank and/ or thesolid/liquid separation unit. The cut-off of the membrane filter of the present disclosure is typically 1-300 kDa and preferably 3-30 kDa, such as 5-15 kDa.

The separation in a settling arrangement according to the present disclosureis based on gravity or centrifugal motion. Equipment for such separation iswell known to the skilled person. The settling arrangement according to thepresent disclosure may be arranged to handle pressurized heat-treated sludgeand generate a pressurized clear fraction. The pressure of such a clearfraction may at least partly drive a downstream membrane filtration of the clear fraction A first configuration of the separation arrangement comprises a settlingarrangement, such as a settling tank, for separating the cooled sludge fromthe arrangement for cooling into a clear fraction and a sediment fraction.Such a settling arrangement is arranged downstream the arrangement forcooling. A benefit of the settling arrangement is that sludge of relatively hightemperature and pressure can be treated in it and that the resulting clearfraction can have a pressure that facilitates a further separation operationand a temperature that facilitates energy-efficient heat-exchange with incoming sludge.

An embodiment of the first configuration comprises a filter, such as amembrane, arranged downstream the settling arrangement for separating theclear fraction into a filtrate and a retentate. The cut-off of a membrane in thisposition is preferably 5-15 kDa. Such an embodiment may further comprise aconduit for recirculating the retentate to the sludge transported from thesludge inlet to the reactor. It may also comprise a heat exchanger arranged totransfer heat from the filtrate to the sludge from the sludge inlet. This heatexchanger may be the heat exchanger arranged on the conduit for preheatingthe sludge discussed above. A filtrate outlet connectable to the sewage treatment plant can be provided such that the filtrate can be returned. 14 An embodiment of the first configuration comprises a sediment separationunit, such as a filter press, arranged downstream the settling arrangement forseparating the sediment fraction into a solids fraction and a liquid fraction.Such an embodiment may further comprise a conduit for merging at leastpart of the liquid fraction from the sediment separation unit with the clearfraction from the settling arrangement, preferably upstream the filter. High-molecular-weight organic compounds and particles of the clear fraction andthe liquid fraction may thus get another chance to agglomerate in the reactor.In addition, formed refractory COD is prevented from leaving the systemthrough the filtrate outlet. Accordingly, formed refractory COD can beprevented from reaching the Wastewater treatment plant. Further, the firstconfiguration may comprise a conduit for merging at least part of the liquidfraction from the sediment separation unit with the sediment fraction fromthe settling arrangement. Such a conduit may comprise a cooler to lower the temperature of the material separated in the sediment separation unit.

A second configuration of the separation arrangement comprises asolid/liquid separation unit, preferably a filter press that separates the cooledsludge from the arrangement for cooling into a solids fraction and a liquidfraction. A cooler may be arranged upstream the solid/liquid separation unitfor further cooling the cooled sludge from the arrangement for cooling. Forexample, a cooler for cooling the cooled sludge prior to the solid/ liquidseparation unit may be arranged upstream the solid/liquid separation unitand downstream the flashing arrangement discussed above. Further, aconduit may be arranged to conduct the cooled sludge from the arrangementfor cooling to the cooler via the heat exchanger arranged on the conduit for preheating the sludge discussed above.

In the second configuration, the heat-treated sludge from the reactor maythus be cooled in three steps: first in the arrangement for cooling, then in theheat exchanger arranged on the conduit for preheating the sludge and finally in the cooler.

The solid/liquid separation of the second configuration normally comprises awater inlet for washing water. A liquid fraction conduit may be arranged toconduct the liquid fraction from the solid/ liquid separation unit to amembrane filter unit for separating the liquid fraction into a filtrate and aretentate. The liquid fraction conduit may comprise a pump to drive theseparation in the membrane filter unit. A retentate conduit may be arrangedto recirculate the retentate such that it is combined with the sludge upstreamthe reactor. Further, a filtrate conduit may be arranged to conduct the filtratefrom the membrane filter unit to a filtrate outlet, which may be connectable to the sewage treatment plant such that the filtrate can be returned.

The reactor of the first aspect is the inventive reactor described below with reference to figure 4, which is a continuous vertical reactor.

In one embodiment, the reactor extends through an opening in an upper wallof the container in an operation mode. Further, reactor may be arranged suchthat it has a generally horizontal orientation in a transportation mode.Accordingly, the reactor can be raised to penetrate the opening in the upperwall of the container on site, e.g. after transport to the site. For example, thereactor may be hingedly attached to the container to allow it to be raised from a transport position to an operation position.

When used according to the first aspect, the reactor comprises at least oneoutlet connected to the arrangement for cooling and at least one recirculationconduit on which the electrical heating arrangement is arranged. In such anembodiment, the reactor is adapted to provide an outlet fraction for leavingthe reactor through the at least one outlet connected to the arrangement forcooling (e.g. the flashing arrangement) and a recirculation fraction forrecirculation in the recirculation conduit, wherein the average particle size islarger in the outlet fraction than in the recirculation fraction. This is achievedas an outlet for the recirculation conduit is arranged above the at least one outlet connected to the arrangement for cooling. 16 The reactor comprises: a reactor inlet arranged at the top of the reactor; afirst channel extending downwardly from the reactor inlet for guiding sludgefrom the inlet to a bottom section of the reactor; and a second channelextending upwardly from the bottom section to the outlet for therecirculation conduit. The second channel is separated from the first channel by at least one wall.

The system according to any one of the preceding claims may furthercomprise a phosphorous separation unit for separating phosphorous from thefirst fraction, the sediment fraction or the solids fraction. However, such aphosphorous separation unit may also be a separate unit arranged outside the container.

The inventive reactor may be used in a method of sludge treatment describedbelow as a second aspect of the present disclosure. The method of the secondaspect, which preferably is a continuous method, is carried out in at least onecontainer, preferably in one container only. Further, the method can be carried out in the system of the first aspect.

The method comprises preheating a sludge to obtain a preheated sludge. Thetemperature of the preheated sludge may for example be at least 90 °C, suchas 90-150 °C. In one embodiment, the preheating comprises the addition ofat least one steam fraction to the sludge. The at least one steam fraction isfurther discussed below. In another embodiment, the preheating comprises indirect heat exchanging (which is also discussed below).

The method further comprises heating the preheated sludge to temperatureof 150-250 °C to obtain a heat-treated sludge. Preferably, the preheatedsludge is heated to a temperature of 150-220 °C, 170-250 °C or 170-240 °C.At such temperatures, the pressure of the sludge is typically 3-50 bar.Electrical heating, heating with steam or another heating method can be used. Electrical heating is preferred.

The method further comprises cooling the heat-treated sludge to obtain cooled sludge. 17 In one embodiment, the cooling is flash cooling such that the at least onesteam fraction used for the preheating is obtained in addition to the cooled sludge.

In another embodiment, the cooling is indirect heat exchanging to achievesaid preheating. Thus, heat may be transferred from heat-treated sludge fromthe heating step to sludge going to the heating step by means of indirect heat- exchangers.

The method further comprises separating the cooled sludge into a firstfraction and a second fraction, wherein the suspended solids content is higher in the first fraction than in the second fraction.

Even though the embodiments of the first aspect discussed above applymutatís mutandis to the second aspect, a few embodiments of the second aspect are discussed below in some detail.

The preheated sludge is further heated in a reactor, in which the sludge isseparated into a recirculation fraction that is recirculated to the reactor andan outlet fraction that is subjected to cooling (e.g. flash cooling). In such anembodiment, the average particle size is preferably larger in the outletfraction than in the recirculation fraction. To achieve such a separation basedon particle size, the separation in the reactor may comprise fluidization or sedimentation of particles of the sludge.

The reactor is the vertical reactor described below with reference to figure 4.The sludge can thus be fed to an inlet at the top of the reactor and guideddownwardly through a first channel in the reactor and then upwardly througha second channel in the reactor. Further, the recirculation fraction can bewithdrawn from the reactor at a position that is located higher up in the second channel than a position at which the outlet fraction is withdrawn.

When the cooling is flash cooling, at least two, such as at least three steam fractions of different temperatures can be obtained and used sequentially in 18 the preheating. Accordingly, the sludge can be first preheated with the steam fraction of the lowest temperature.

The separation of the cooled sludge into a first fraction and a second fractionmay for example comprise settling and/ or filter pressing. In addition, the separation may comprise membrane filtration.

In one embodiment, the separation comprises settling to obtain a clearfraction and a sediment fraction. In such an embodiment, the clear fractionmay be subjected to filtering, such as membrane filtering, to obtain a filtrateand a retentate. The retentate can for example be recirculated such that it iscombined with the sludge and heat-treated. Further, the filtrate can forexample be used for heating the sludge upstream of the preheating in a heatexchange operation. The sludge can thus be heated first by the filtrate andthen by the at least one steam fraction or the indirect heat exchanging on itsway to the reactor. The sediment fraction from the settling can for example beseparated into a solids fraction and a liquid fraction, preferably by means of afilter press. At least part of the liquid fraction can then be merged with theclear fraction from the settling and thus subjected to the filtering. At least part of the liquid fraction can also be merged with the sediment fraction.

In another embodiment (corresponding to the second configuration of theseparation arrangement of the first aspect), the separation comprisesseparation of the cooled sludge by filtering, such as filter pressing (withoutprior settling) into a solids fraction and a liquid fraction. The cooled sludgemay be subjected to additional cooling before such filtering. Such additionalcooling may be carried out in a cooler. Alternatively or complementary, thecooled sludge may be further cooled by heat exchange with the incomingsludge prior to the preheating. The liquid fraction may be subjected tomembrane filtering such that a filtrate and a retentate are obtained. Theretentate may be recycled and thereby combined with the sludge prior to the further heating and preferably also prior to the preheating. 19 One embodiment of the method further comprises separation of phosphorusfrom the first fraction, the sediment fraction or the solids fraction. However,such separation may also be carried out outside the container in a method separate from the method of the second aspect.

EXAMPLES Figure 1 illustrates an embodiment of a container 100 for treatment of sludgefrom a sewage treatment plant. As all standardized containers, the container100 has a housing 101 comprising a horizontal bottom wall, a horizontal topwall and two pairs of opposed vertical side walls. The walls are normallycomposed of steel. Further, the container 100 is adapted to be loaded on andoff a truck capable of transporting the container 100. For example, thecontainer 100 can be conveniently transported from the site where it isproduced/assembled to the site of the sewage treatment plant. Consequently,the container format enables standardized production / assembly. Further, thecontainer 100 can be conveniently picked up at the site of the sewagetreatment plant for service, if necessary. In such case, the truck picking upthe container 100 can bring a replacement container 100, which minimizes the interruption of operation.

The container 100 comprises a sludge inlet 102a. It may for example bearranged in the housing 101. The sludge inlet 102a is connectable to a sludgeoutlet of the sewage treatment plant. Inside the housing 101 of the container100, a sludge silo 102 is arranged to collect sludge fed to the container 100from the sewage treatment plant via the sludge inlet 102a. The sludge silo 102is connected to a conduit 103 for conducting sludge from the sludge silo 102to a vertical reactor 104 (a more detailed embodiment of a suitable vertical reactor is described below with reference to figure 4).

At least one pump 105 is arranged on the conduit 103. Further, a heat exchanger 106 for preheating the sludge may be arranged on the conduit 103.The conduit 103 comprises at least one steam mixer 107 by means of which atleast one steam fraction is mixed into the sludge to (further) preheat it. If the heat exchanger 106 is included, the at least one steam mixer 107 is / are arranged downstream the heat exchanger 106. The at least one steam mixer107 may for example be at least one venturi steam mixer or at least onemechanical re-compressor with steam nozzle mixer. The former alternative isconsidered to be more easily implemented in the system. The temperature ofthe sludge after the at least one steam mixer is preferably at least 90 °C, such as 90-150 °C.

A booster pump 103b may be arranged on the conduit 103 between the atleast one steam mixer 107 and the vertical reactor 104. The effect of such apump 103b may be to further increase the pressure in the conduit to overcome the higher pressure in the reactor.

At the top of the vertical reactor 104, a reactor top inlet 108 is arranged. Theconduit 103 connects to the reactor top inlet 108. The vertical reactor 104further comprises a recirculation conduit 109 on which an electrical heater110 is arranged. However, the electrical heater can be omitted if thecomposition of the sludge and the conditions in the reactor are such thatexothermic reactions provide sufficient heat. The downstream end of theconduit 103 and the reactor top inlet 108 can be part of the recirculationconduit 109. Accordingly, the conduit 103 may comprise a recirculation conduit inlet 111 arranged downstream the at least one steam mixer 107.

In the vertical reactor 104, the sludge is heat-treated, preferably underhydrothermal carbonization conditions, which means that no oxygen is addedand that the temperature is 150-250 °C, preferably 170-240 °C. During theheat treatment, particles in the sludge agglomerate to form larger particles,which agglomeration facilitates downstream separation of suspended solids.The vertical reactor 104 comprises a recirculation conduit outlet 112 throughwhich a recirculation fraction is led from the vertical reactor 104 into therecirculation conduit 109. The vertical reactor 104 further comprises at leastone reactor sludge outlet 113 through which a heat-treated sludge fraction(also referred to as an “outlet fraction”) is fed to a flashing arrangement 114.The recirculation conduit outlet 112 is preferably arranged above the at least one sludge outlet 113. In such case, fluidization or sedimentation principles 21 can be utilized such that the average particle is larger in the heat-treatedsludge fraction than in the recirculation fraction. Further, the smallerparticles of the recirculation fraction pass the vertical reactor 104 again andget another chance to agglomerate. Further, refractory components in therecirculation fraction are recycled to the reactor 104, which decreases their concentrations in the outlet fraction.

The recirculation conduit may comprise a bottom feed conduit 109a, whichconnects to a reactor bottom inlet 109c arranged at the bottom of the verticalreactor 104. When such a bottom feed conduit 109a is included, it routes atleast part of the recirculation fraction to the bottom of the vertical reactor 104, which may improve fluidization in the vertical reactor.

It is possible to replace the vertical reactor 104 with another reactor that isalso capable of heat-treating the sludge under hydrothermal carbonizationconditions. The embodiment of figure 1 as well as the embodiments of figures2 and 3 discussed below are thus not necessarily limited to the vertical reactor 104 discussed above.

The flashing arrangement 114 preferably comprises at least one flash tank 115in which the heat-treated sludge is cooled by a pressure reduction also knownas “flashing” and the at least one steam fraction added to the sludge in the atleast one steam mixer 107 is/ are produced. When the flashing arrangement114 comprises more than one flash tank 115, they are preferably arranged in series (figure 1 shows three flash tanks 115 arranged in series).

The container further comprises a steam routing arrangement 116 for routingthe at least one steam fraction from the flashing arrangement 114 to the atleast one steam mixer 107. Preferably, the steam routing arrangement 116comprises at least one steam conduit 117, wherein each steam conduit 117connects a flash tank 115 to a steam mixer 107. In such case, a steam conduit117 can connect the flash tank 115 arranged furthest upstream to the steammixer 107 arranged furthest downstream and another steam conduit 117 can connect the flash tank 115 arranged furthest downstream to the steam mixer 22 107 arranged furthest upstream. Thereby, an efficient preheating sequence is obtained.

A settling tank 118 for separating the cooled sludge from the flashingarrangement 114 into a clear fraction and a sediment fraction is arrangeddownstream the flashing arrangement 114. The settling tank 118 can bepressurized, which means that the pressure of the cooled sludge from theflashing arrangement 114 is still above atmospheric when it reaches thesettling tank. A membrane filter unit 119 can be arranged downstream thesettling tank 118 for separating the clear fraction into a filtrate and aretentate. The membrane filter unit 119 can comprise a pump 120 for drivingthe separation. If the settling tank is pressurized, the energy input in thepump 120 can be reduced. If the pressure in the settling tank 118 is high enough, the pump 120 can be omitted.

A retentate conduit 121 may be arranged to recirculate the retentate to aretentate inlet 122 on the conduit 103. Thereby, the retentate may becombined with untreated sludge and heat-treated again, which means thathigh-molecular-weight organic compounds and small particles of theretentate, which are relatively small, can get another chance to agglomerate.Combining the retentate with the untreated sludge may thus increase theoverall yield of solid material and reduce the amount of COD leaving thesystem. Further, a filtrate conduit 123 may be arranged to conduct the filtratefrom the membrane filter unit 119 to the heat exchanger 106, in which itpreheats the incoming sludge. A filtrate outlet 124 may be arrangeddownstream the heat exchanger 106. The filtrate outlet 124 may beconnectable to the sewage treatment plant such that the filtrate can be returned.

A sediment conduit 125 may be arranged to conduct the sediment fractionfrom the settling tank 118 to a solid/liquid separation unit, preferably a filterpress 126, that separates the sediment fraction into a solids fraction and aliquid fraction. The filter press 126 normally comprises a water inlet 126a for washing water. A first liquid fraction conduit 127 may be arranged to merge a 23 first part of the liquid fraction from the filter press 126 with the clear fractionfrom the settling tank 118. If the membrane filter unit 119 is included, saidfirst part of the liquid fraction and the clear fraction are merged upstream ofit. A second part of the liquid fraction from the filter press 126 may berecirculated. For example, a second liquid fraction conduit 128 may bearranged to merge the second liquid fraction with the sediment fraction fromthe settling tank 118. Such a second liquid fraction conduit 128 may comprise a cooler 128a for cooling the second liquid fraction.

The settling tank 118, membrane filter unit 119, the filter press 126 and theassociated conduits together forms an embodiment of a separationarrangement for separating the cooled sludge from the flashing arrangement114 into a first fraction (in this embodiment the solids fraction from the filterpress 126) and a second fraction (in this embodiment the filtrate from themembrane filter unit 119), wherein the suspended solids content is higher in the first fraction than in the second fraction.

A solids fraction outlet 129 may be arranged downstream the filter press 126.The solids fraction from the solids fraction outlet 129 may be further treatedin a phosphorus separation unit 130. If the filter press 126 is not included, thesediment fraction from the settling tank 118 can be further treated in the phosphorus separation unit 130.

The phosphorus separation unit 130 can be arranged inside the housing 101of the container 100. Due to the limited space available in the container 100,it may however be preferred that the phosphorus separation unit 130 is separate from the container 100.

In any case, the phosphorous separation unit 130 may comprise a first mixingunit 131, such as a stirred tank, for mixing the solids fraction with acid andoptionally with water to obtain an acidified product that preferably has a pHof 3-4, at which phosphorous is dissolved together with part of the heavymetal content of the incoming solids fraction. The mixing unit 131 may thus comprise a water inlet and an acid inlet. The water inlet and the acid inlet 24 may be the same inlet or two different inlets. The phosphorous separationunit 130 further comprises a first separation unit 132, such as a filter press,arranged downstream the mixing unit 131. The function of the firstseparation unit 132 is separation of the acidified product into a fuel fractionand acidified liquid fraction comprising dissolved phosphates. The firstseparation unit 132 can alternatively be the same filter press as unit 126 andoperate by alternatively dewatering and washing the sediment fraction andoutlet from the stirred tank 131. The fuel fraction is recovered from thephosphorous separation unit 130 through a fuel fraction outlet 133. The firstseparation unit 132 may comprise a water inlet 132a for washing water. Asecond mixing unit 134, such as a stirred tank, is arranged downstream thefirst separation unit 132. In the second mixing unit 134, lime can be added tothe acidified liquid fraction such that a neutralized slurry comprisingprecipitated phosphates is obtained. To separate the neutralized slurry into asolids fraction comprising precipitated phosphates and a liquid effluentfraction, a second separation unit 135 is arranged downstream the secondmixing unit 134. The liquid effluent fraction can for example be returned tothe sewage treatment plant and/ or treated further for separate removal ofdissolved heavy metals. The solids fraction comprising precipitatedphosphates can, optionally after refining, be used in the production of a fertilizer.

A gas treatment unit 140 may be arranged in the container 100 and one ormore conduits may be arranged to conduct gases from the sludge silo 102, thevertical reactor 113 and/ or the settling tank 118 to the gas treatment unit 140.The gas treatment unit 140 may for example comprise a condenser 141 forseparating gases into a condensed fraction and a gaseous fraction. Acondensed fraction conduit 142 may be arranged to recirculate the condensedfraction from the condenser 141 to the conduit 103. The condensed fractioncan thus be mixed with the incoming sludge. The gas treatment unit 140 mayfurther comprise a carbon filter 143 arranged downstream the condenser topurify the gaseous fraction. Another means for removing trace hydrocarbons can be used instead of the carbon filter.

Figure 2 illustrates another embodiment of a container 100 for treatment ofsludge from a sewage treatment plant. In the embodiment of figure 2, the atleast one steam mixer 107, the flashing arrangement 114 and the steamrouting arrangement 116 of the embodiment of figure 1 are replaced with anarrangement 207 for indirect heat exchange. Otherwise, the components ofthe embodiment of figure 2 are as in the embodiment of figure 1. In thearrangement 207 for indirect heat exchange, heat is transferred from theheat-treated sludge fraction to the sludge in the conduit 103 without directcontact. The heat-treated sludge is thus kept separate from the sludge conducted in the conduit 103.

The arrangement 207 for indirect heat exchange may comprise a series ofindirect heat exchangers 207a, 207b, 207c, which may be selected from tubular heat exchangers and plate heat exchangers.

Figure 3 illustrates another embodiment of a container 100 for treatment ofsludge from a sewage treatment plant. In the embodiment of figure 3, theseparation arrangement for separating the cooled sludge from the flashingarrangement 114 into the first fraction and the second fraction (wherein thesuspended solids content is higher in the first fraction than in the secondfraction) is different compared to the embodiment of figure 1. Otherwise, thecomponents of the embodiment of figure 3 are as in the embodiment of figure 1.

In the embodiment of figure 3, the separation arrangement comprises asolid/liquid separation unit 301, preferably a filter press, that separates thecooled sludge from the flashing arrangement 114 into a solids fraction and aliquid fraction. Before the solid/ liquid separation unit 301, the cooled sludgemay be subjected to further cooling. For example, a cooler 302 for cooling thecooled sludge prior to the solid/liquid separation unit 301 may be arrangedupstream the solid/ liquid separation unit 301 and downstream the flashingarrangement 114. Further, a conduit 303 for the cooled sludge may bearranged to conduct the cooled sludge from the flashing arrangement 114 to the cooler 302 via the heat exchanger 106. The sludge from the reactor 104 26 may thus be cooled in three steps: first in the flashing arrangement 114(which may comprise several flashing stages), then in the heat exchanger 106 and finally in the cooler 302.

The solid/liquid separation unit 301 normally comprises a water inlet 301afor washing water. A liquid fraction conduit 305 may be arranged to conductthe liquid fraction from the solid/liquid separation unit 301 to a membranefilter unit 307 for separating the liquid fraction into a filtrate and a retentate.The liquid fraction conduit may comprise a pump 306 to drive the separationin the membrane filter unit 307. A retentate conduit 308 may be arranged torecirculate the retentate to a retentate inlet on the conduit 103. Thereby, theretentate may be combined with untreated sludge and heat-treated again,which means that high-molecular-weight organic compounds and smallparticles of the retentate, which are relatively small, can get another chanceto agglomerate. Combining the retentate with the untreated sludge may thusincrease the overall yield of solid material. Further, a filtrate conduit 309 maybe arranged to conduct the filtrate from the membrane filter unit 307 to afiltrate outlet 124, which may be connectable to the sewage treatment plant such that the filtrate can be returned.

Figure 4 illustrates an embodiment of a continuous vertical reactor 404according to the present invention, which is designed to treat pressurizedaqueous sludge having a temperature of at least 150 °C. Preferably, thereactor is designed to treat such sludge having a temperature of 200-250 °C and a pressure of 15-50 bar.

The reactor 404 comprises a reactor top inlet 408 arranged at a top section405 of the reactor 404. A first channel 401 extends downwardly from thereactor top inlet 408 for guiding sludge from the reactor top inlet 408 to abottom section 406 of the reactor 404. Further, a second channel 402extends upwardly from the bottom section 406. At least one separation wall403, which preferably is essentially vertical, separates first channel 401 from the second channel 402. At the bottom section 406 of the reactor 404, there 27 is provided an opening 407 through which sludge may flow from the first channel 401 into the second channel 402.

The reactor 404 comprises at least one upper outlet 412 arranged at thesecond channel 402 to connect to a recirculation conduit 409 forrecirculation of a fraction of the heat-treated sludge (a “recirculationfraction”). The reactor 404 is thus designed to allow sludge to flow from theopening 407 through the second channel 402 to the upper outlet 412. Therecirculation conduit 409 preferably comprises a heater, such as an electrical heater, for heating the recirculation fraction.

The reactor 404 further comprises at least one lower outlet 413 that can beconnected to an arrangement for cooling heat-treated sludge, such as theflashing arrangement 114 of figure 1 and 3 or the arrangement 207 for indirect heat exchange of figure 2.

The at least one lower outlet 413 is/ are arranged below the at least one upperoutlet 412. Consequently, the average particle size will be larger in the heat-treated sludge that leaves the reactor 404 through the at least one loweroutlet 413 than in the recirculation fraction in the recirculation conduit 409.The reason for the difference in particle size is the fluidization obtained in thesecond channel 402. To aid the fluidization, the reactor 404 may comprise abottom inlet 409c arranged at the bottom section 406 of the reactor 404. Thebottom inlet 409c can for example be connected to the recirculation conduit409 such that part of the recirculation fraction can be recirculated to the bottom inlet 409c.

The reactor 404 may comprise an outer wall 414 which is also an outer wall ofthe second channel 402. Further, the separation wall 403 may constitute aninner wall of the second channel 402 and an outer wall of the first channel401. For example, the separation wall 403 may be a pipe extendingdownwardly from the reactor top inlet 408 to the bottom section 406 of thereactor 404. Such a pipe may have an essentially circular cross-section.

Further, the outer wall 414 may comprise a tubular section 415 having an 28 essentially circular cross-section. In such case, the pipe and the tubularsection 415 may be concentric. In one embodiment, the outer wall has threemajor sections: the tubular section 415; a bottom wall section below thetubular section 415 at the bottom section 406 of the reactor 404; and a topwall section above the tubular section 415 at the top section 405 of the reactor404. The bottom wall section and/ or the top wall section may for example be shaped as a cone, a truncated cone or a half sphere.

A gas outlet 416 may be arranged at a top section 405 of the reactor 404 to allow gases formed in the reactor to be purged.

Claims (14)

1. A continuous vertical reactor (404) designed to treat pressurizedaqueous sludge having a temperature of at least 150 °C, which reactor (404)comprises a reactor top inlet (408) arranged at a top section (405) of thereactor (404), wherein: a first channel (401) extends downwardly from the reactor top inlet (408)for guiding sludge from the reactor top inlet (408) to a bottom section (406)of the reactor (404); a second channel (402) extends upwardly from the bottom section (406); at least one separation wall (403), which preferably is essentially vertical,separates first channel (401) from the second channel (402); and an opening (407) through which sludge may flow from the first channel(401) into the second channel (402) is provided at the bottom section (406)of the reactor (404),wherein the reactor (404) further comprises: at least one upper outlet (412) arranged at the second channel (402) toconnect to a recirculation conduit (409) for recirculation of a fraction of theheat-treated sludge; and at least one lower outlet (413) that can be connected to an arrangement forcooling heat-treated sludge, which at least one lower outlet (413) is/ arearranged below the at least one upper outlet (412), characterized in that the reactor (404) further comprises a bottom inlet (409c) arranged at the bottom section (406) of the reactor (404).

2. The reactor (404) of claim 1, wherein the bottom inlet (409c) isconnected to the recirculation conduit (409) such that part of the fraction of the heat-treated sludge can be recirculated to the bottom inlet (409c).

3. The reactor (404) of any one of the preceding claims, wherein therecirculation conduit (409) comprises a heater, such as an electrical heater, for heating the fraction of the heat-treated sludge.

4. The reactor (404) of any one of the preceding claims, wherein theseparation wall (403) constitutes an inner wall of the second channel (402) and an outer wall of the first channel (401).

5. The reactor (404) of any one of the preceding claims, wherein theseparation wall (403) is a pipe extending downwardly from the reactor top inlet (408) to the bottom section (406) of the reactor (404).

6. The reactor (404) of claim 5, wherein the pipe has an essentially circular cross-section.

7. The reactor (404) of any one of the preceding claims, furthercomprising an outer wall (414) which is also an outer wall of the second channel (402).

8. The reactor (404) of claim 7, wherein the outer wall (414) comprises a tubular section (415) having an essentially circular cross-section.

9. The reactor (404) of claim 8 comprising a pipe according to claim 5 or 6, wherein the pipe and the tubular section (415) are concentric.

10. The reactor (404) of claim 8 or 9, wherein the outer wall has threemajor sections: the tubular section (415); a bottom wall section below thetubular section (415) at the bottom section (406) of the reactor (404); and atop wall section above the tubular section (415) at the top section (405) of thereactor (404).

11. The reactor (404) of claim 10, wherein the bottom wall sectionand/ or the top wall section is/ are shaped as a cone, a truncated cone or a half sphere.

12. The reactor (404) of any one of the preceding claims, furthercomprising a gas outlet (416) arranged at the top section (405) of the reactor (404) to allow gases formed in the reactor to be purged.

13. A system (100) for s1udge treatment, which system is arranged in acontainer adapted to be transported by a truck and comprises: a s1udge in1et (102a) for receiving a s1udge; a continuous vertical reactor (404) according to any one of claims 1-12comprising an arrangement (110) for heat treatment of the s1udge, whichreactor (404) is arranged downstream the s1udge in1et (102a); an arrangement (114, 207) for coo1ing s1udge treated in the reactor, whicharrangement (114, 207) is arranged downstream the reactor (404); and a separation arrangement for separating the coo1ed s1udge into a firstfraction and a second fraction, wherein the suspended so1ids content is higher in the first fraction than in the second fraction.

14. A method of s1udge treatment, which method is carried out in a container adapted to be transported by a truck and comprises: preheating a s1udge to obtain a preheated s1udge; further heating the preheated s1udge to temperature of 150-250 °C using acontinuous vertical reactor (404) according to c1aim 1 to obtain a heat-treateds1udge; coo1ing the heat-treated s1udge to obtain a coo1ed s1udge; separating the coo1ed s1udge into a first fraction and a second fraction,wherein the suspended so1ids content is higher in the first fraction than in the second fraction.