Performing Centralized Industrial Wastewater
treatment service at Zero Waste Discharge
3V Green Eagle
Muscat, 18 March 2015
Summary
1.
3V Group and 3V Green Eagle
2.
Areas of Practice
3.
Performing Zero Waste Discharge Industrial Wastewater Treatment
4.
Research & Development
2
3V Group at a glance
 Founded in 1958 providing fine chemicals production, process and equipment solution,
environmental technologies and waste treatment operation and management
 Focused on technology, characterized by:
 Interdisciplinary capabilities and skills;
 In-house Research & Development;
 In-house Engineering Capabilities (Italy, USA);
 Patented innovative technologies;
 Design & Build, Operate & Mantain Wastewater & Sludge Treatment Center;
 Same ownership since 1958
3
3V Group – Milestones (1/2)
 1958:
 1960/70:
 1976:
 1978:
 1987:
 1990:
 2000:
First chemical production activities
Industrial development of chemical production and international operations
3V Group starts designing and constructing equipment and process system for
manufacturing industry
3V Group develops a chemical production site in the United States (3V Incorporated);
Joint Venture with ENI for developing innovative chemical products (CPM Company in
Porto Marghera, Venice);
3V develops and internal treatment center for wastewater and contaminated sludge
3V Green Eagle is formed in order to further develop and grow wastewater treatment
and environmental services
(continues)
4
3V Group - Milestones




2003:
2006:
2008:
2014:
 2014:
3V Group enters thermal treatment equipment market (3V MABO);
TOP® technology is classified as “Best Available Technique” by EU-IPPC Commission
3V Group enters Glass Lining market (3V Glasscoat);
3V Group and TREVI incorporate the new Company “6V”, which aims to develop and
promote environmental technologies for remediating Contaminated Sites;
3V Green Eagle and 3V Tech are awarded by an international Oil&Gas EPC Contractor
with no. 2 important contracts for providing a TOP® - Wet Oxidation Unit for “Spent
Caustic” wastewater treatment for two relevant Refinery in the Middle East (Oman,
Saudia Arabia)
5
3V Group – Areas of Activity
Family owned, 650 employees, 200 million Euros of yearly turnover
6
3V Chemical Company – Areas of Activity
3V Chemical Company è attiva nei seguenti settori:
1. Performance Division: involves production of additives for the textile, plastics, coating, adhesive, ink and
petrochemical industries, and consist mainly in the following products:
OPTICAL BRIGTHENERS (OPTIBLANC©); UV-FILTERS (UVASORB©); ACRYLIC THICKENERS (NOVAPRINT© AND POLYGEL©);
ANTIOXIDANTS (ALVINOX©); FLAME RETARDANTS (PLASTISAN©); ANTISTATIC AGENTS (ANTISTATICO©); SUSPENDING AGENTS
(POLIVIC©); ANTIFOULING AGENTS (EVERCLEAN©); POLYMERISATION INHIBITORS and STOPPERS (TEMPOXY©); TEXTILE AUXILIARIES
2. Industrial Division: provides products and services for paper, building&construction industries and for
swimming pool sanitizing, and consist mainly in the following products:
OPTICAL BRIGTHENERS (OPTIBLANC©); ACRYLIC THICKENERS (POLYGEL©); FLUORESCENCE QUENCHERS (NOFLUOR©); PAPER
AUXILIARIES; WATER REDUCERS (DEGAL©); SUPERPLASTICIZERS (NIMEXOL©); TRICHLORO ISO-CYANURATE and SODIUM DICHLORO
ISO-CYANURATE SALT (OXIDAN©)
3. Specialty Division: involves chemicals for Detergent, Cosmetic, Toiletry and Pharmaceutical applications:
SYNTHETIC POLYMERS (POLYGEL© and SYNTHALEN©); UV-FILTERS (UVASORB©); CONDITIONING POLYMERS (CONDITIONER©);
PRESERVATIVES and ANTIBACTERIALS (ABIOL©); in addition to OPTICAL BRIGTHENERS (OPTIBLANC©) and CHLORO ISO-CYANURATES
(OXIDAN©)
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3V Tech – Main Activities
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3V Group – International Presence
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3V Green Eagle
Areas of Practice
From Chemistry to Environment
Industries served by 3V Green Eagle
3V Green Eagle provides services for Manufacturing, Municipal, Oil&Gas and Remediation Industry
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3V Green Eagle
Technologies Portfolio
From Chemistry to Environment
Technologies Portfolio
1. TOP® Technology:
• TOP® - Wet Oxidation for Wastewater
• TOP® - Wet Oxidation for Spent Caustic Wastewater
• TOP® - Wet Oxidation for Sludge
• DUAL TOP® - Wet Oxidation for Sludge & Wastewater combined
2. Enhanced Biological Treatment
3. Wastewater concentration & drying
4. Zero Liquid Discharge (ZLD)
5. Oil & Solvent recovery
6. Soil & Sediment Washing
7. Pyrolysis
8. Thermal Desorption
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TOP® Technology
Wet Oxidation
1 - What is Wet Oxidation ?
Wet Oxidation is the oxidation of dissolved or suspended components in water using oxygen as the oxidizer. The reaction is
activated by injecting pure Oxygen in a high pressure reactor, and it allows to “burn in water - flameless” dissolved
compounds, including recalcitrant compounds with very low biodegrability.
1- Wet Oxidation Application by 3V Green Eagle
3V Green Eagle has named its own Wet Oxidation application as
TOP® (acronym for Temperature, Oxygen and Pressure)
The Wet Oxidation process is implemented at an industrial scale at 3V’s Green
Eagle’s Environmental Center in Grassobbio, Bergamo, Italy.
1.The Grassobbio center is authorized for treating up to 400.000 m3/year
2.Accepts up to 295 different waste categories;
3.The facility has a TOP ® Process (wastewater), a Dual TOP ® Process (sludge), a
chemical-physical unit and a biologic unit and a stripping unit;
4.Serves approximately 200 Clients in Italy;
5.Facility operational since 1990.
3V Green Eagle Wet Oxidation Process is patented as “TOP ®” (Temperature,
Oxygen, Pressure). Other plants were built for the 3V Group in Mozzo, near
Bergamo and Porto Marghera, near Venice
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Why is Wet Oxidation innovative, compared to traditional water or
sludge treatment?
Wet Oxidation achieves Contaminant Destruction at Zero Discharge
“Wet oxidation” allows total chemical compounds destruction.
However:
• Chemical-Physical water treatment usually transfers contaminants
from wastewater to wastewater sludge;
• Biological process is not adequately effective on high COD waters,
and does not allow destruction of complex chemical, toxic or
recalcitrant compounds (biologic reactors, anaerobic digestors);
• Besides solvent-rich streams, Incineration is not cost effective on
liquid waste with moderate to high water content. In addition to
ash, incineration can also produce additional contaminants
(dioxins and other micro-pollutants);
• Sludge disposal to Landfill or Agriculture does not provide a
sustainable long-term solution.
Wet oxidation can treat both wastewater and sludge at the same
facility, obtaining high process efficiency and profitability.
1 - TOP®: main advantages
1.
Continuous Operation (24/7)
2.
Highly Automated (DCS/PLC Controlled)
3.
Reduced utilities consumption – high energy recovery
4.
Flexibility: treats a wide variety of liquid waste categories
5.
Extremely low gaseous emissions (limited to CO2 and O2)
6.
No toxic air emissions
liquid
7.
Achieve total contaminant destruction: resulting effluent highly
biodegradable
solid
8.
Heavy Metals total oxidation – Ammonia stripping
9.
Inorganic Fraction Reuse (TOP Filler)
TOP Unit
Emission:
air
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TOP®: Reduced Utilities Consumption
Electric Energy (15-18 KWh/ton):
• Electric Energy Consumption is mainly
limited to high pressure pumps (liquid
waste, oxygen)
Natural Gas (15-20 Nmc/ton):
• Natural Gas consumption is limited to
liquid waste pre-heating as wet oxidation
reaction is strongly exothermic and
reaction thermal energy is recovered with
high efficiency
Liquid Oxygen (60-90 Kg/ton)
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1 - TOP®: Limited surface area occupation
3V Green Eagle Treatment Center covers a limited surface area:
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1 - Largest Wastewater & Sludge treatment center in Italy
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1 - TOP® technology – Wet Oxidation – BAT (EU IPPC, 2006)
3V Green Eagle operates its Wet Oxidation technologies since 1990 and has
received important awards and recognitions, as well as involvement in
international projects regarding the definition of technological Best
Practices for sludge treatment, as listed below:
•
in 2006 TOP® and Dual TOP® technologies were recognized as "Best
Available Techniques" for Wastewater and Sludge Treatment by EUIPPC Commission.
•
3V Green Eagle is currently participating to EU-funded ROUTES
project, in order to investigate the effect of different operating
parameters (i.e. temperatures, reaction time, oxygen dosage) on the
efficiencies of an industrial scale Wet Oxidation (TOP® and Dual TOP®
technologies), with different kinds of sludge produced by Sewage
Wastewater biological treatment (www.en-routes.org)
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1 - TOP® and Dual TOP® are Best Available Technique
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1 - TOP® and Dual TOP®: industry of applications
Detergents
Chemical
Resins
Glues
Pharmaceutical
Cosmetics
Pesticides
Photo printing
Antibiotics
Colouring
Toxic wastewater from
hospitals
Food
Oil&Gas
Textile
Press
Paints
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TOP®: Multi-Stream Process Performance
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TOP® - Micro-Pollutants Reduction
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TOP® technology enhances Biological Treatment
3V Green Eagle has extensive experience in biological treatment plant
management and fine-tuning. The TOP®/DUAL TOP® liquid effluent is warm and
extremely biodegradable and therefore it will ensure a constant availability of a
good biodegradable influent to the MBR. This aspect is particularly important in
the case of sensitive reaction kinetics like the ones related to nitrogen
removal are.
We use the effluent of Wet Oxidation as a carbon source for
denitrification process. The effluent is used efficiently from biomass and allows
high speed biological denitrification (Ref. Strong et al. - 2011)
Finally, the potential occurrence of micropollutants adsorbed in the sludge from
the MBR system, due to industrial wastewaters, will be further removed during
the DUAL TOP® - Wet Oxidation process, avoiding the release of recalcitrant
contaminants into the environment.
All the above allows us to treat the incoming industrial wastewater
with excellent removal efficiencies for all the required parameters, with a
combined sustainable sludge management.
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Dual TOP®
Wet Oxidation for Wastewater & Sludge Combined
Municipal Sludge Treatment - Introduction
3V Green Eagle's Dual TOP® - Wet Oxidation technology for sludge and
wastewater combined allows the simultaneous treatment of:
1. Activated sludge from biological plants in the industrial or civil
industry
2. Industrial wastewater
3. Landfill leachates with high COD levels
4. Highly contaminated sediments (marine, fluvial, etc)
5. Other liquid or wastewater streams which can be pumped.
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Municipal Sludge Treatment - Introduction
The Dual TOP® technology is capable of:
• Treat a mix of industrial wastewater, sludge and/or port sediments with a COD between 20.000
and 100.000mg/L. In addition, it is able to degrade more than 99.9% of pollutants which are
present.
• Reduce the COD of the sludge/water mix up to 85%
• Reduce volatile suspended solids contained in the sludge by 96% to 98%
• Recover heat from the oxidation process to dry the inorganic residue output
• Maintain more moderate and safe operating conditions, including temperature and pressure,
than those used for the TOP® - Wet Oxidation for wastewater technology.
• Establish a zero discharge process which does not produce any solid waste and no air emissions
• Eliminate almost all of the organic fraction which produces a stable, mainly inorganic material
that is rich in calcium and phosphorous, named “TOP FILLER”. This material can also be reused as
a primary-secondary material. In 2013, our solid residue obtained the CE mark which allows it to
be used as a filler for bituminous materials and similar matters.
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Dual TOP®: treatment at Zero Discharge
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Dual TOP® - Sludge & Industrial Wastewater Combined
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CE Certificate for TOP Filler Reuse
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Potential TOP® Filler Reuse Options
Spherapor is a Lightening Structuring material; it is characterized by an open porosity. This feature prevents
water absorption, whatever the application in which Spherapor is used, thus ensuring the high lightness of
the final product. Mechanical strength up to 5 times higher than that of the reference products on the
market it is combined with the low specific gravity; lightness and mechanical strenght, as well as a very high
chemical inertness, make Spherapor a highly innovative solution for Lightweight Concrete, or Glue, markets
particularly for the construction sector.
34
EU funded project on Sludge Treatment – Project Routes
Project Routes (“Innovative
solutions for civil sludge
treatment”) is financed by
European Union (Call FP7-ENV
2010)
17 partner, including Italy(5),
Germany (4), Sweden (2), Poland
(2), France (1), Spain (1),
Switzerland (1) and Canada (1).
Project has started in May 2011
and was completed in May 2014
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Wastewater Concentration
3 - Wastewater concentration & drying
3V Green Eagle uses evaporation technology that has the following advantages
for wastewater concentration:
• Max volume reduction of effluent up to 1-3% of water content (low disposal
cost)
• Possible recovery of valuable substances in the concentrate
• Recycling of condensate (distillate) as process water
• Negligible use of chemical substances
3V Green Eagle always tries to apply techniques to minimize energy
consumption for its evaporation plants. Some of the options we apply:
• Multiple effect arrangement (ME)
• Thermal vapor recompression (TVR)
• Mechanical vapor recompression (MVR)
• Use of energy from waste
Our evaporation plants can be supplied as a skid-mounted unit or are suitable
for on-site installation.
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MVR FALLING FILM EVAPORATOR
Waste salty stream, chemical company, Saudi Arabia
Single effect falling film preconcentrator, heated by MVR
(centrifugal fan), operating
under vacuum.
Concentration of mixed salts
solution from 5%TS to 20%
approx.
Evaporation capacity: approx.
25 ton/h.
2 – Examples of Skid Mounted Units (Concentration)
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Zero Liquid Discharge
(ZLD)
4 - Zero Liquid Discharge (ZLD)
Zero Liquid Discharge (ZLD) is an industrial plant without
discharge of wastewater. This target is usually reached by
separation into evaporation/crystallization plants, where
contaminant elements are discharged as solid waste and
the condensate is recovered in the process. Normally, the
effluent is a salty solution and the thermal separation is
the final step of ZLD, after pre-treatments, ultrafiltration
and reverse osmosis units.
ZLD technology offers the following advantages for
wastewater concentration:
• no wastewater discharge, just waste solids to disposal
• max volume reduction of effluent up to 3% of water
content (low disposal cost)
• recycling of condensate (distillate) as process water
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FORCED CIRCULATION CRYSTALLIZER
Waste salty stream, disposal company, Italy (ongoing project)
Skid mounted plant
Single effect forced circulation
crystallizer heated by hot water,
operating under vacuum.
1.000 kg/h mixed salts solution from
40%TS to salt cake < 10% residual
moisture. Solid discharge by
worm/screen centrifuge.
Evaporation capacity: approx. 600
kg/h.
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TRANSPORTABLE FORCED CIRCULATION EVAPORATOR AND
CRYSTALLIZER (ongoing project)
Waste RO reject, major oil & gas company, Italy
Evaporator module
Crystallizer module
No. 2 modules, no. 3 skids/each
Single effect forced circulation
evaporator and crystallizer, both
heated by MVR (roots compressor),
operating under vacuum.
6.200 kg/h mixed salts solution from
6%TS to salt cake < 10% residual
moisture. Solid discharge by
worm/screen centrifuge.
Evaporation capacity: approx. 6.000
kg/h.
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Oil & Solvent Recovery
5 - Oil & Solvent recovery (1/2)
As many industrial processes need to minimize wastewater and recover reusable fraction to
maximum extent, evaporation, stripping and distillation techniques play an important role in the
manufacturing industry and also in the field of environmental technology.
Our systems recover solvents from the effluent, then clean and prepare the product for reuse
and/or purify the liquid stream from volatile products for further processing.
Our systems operate under pressure or under vacuum and can be designed for single-duty or multipurpose operation.
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5 - Oil & Solvent recovery (2/2)
Oil&Solvent recovery is based on the following technologies:
• Stripping by steam or other gas for removal of VOC, ammonia, etc. from liquid
streams.
• Distillation for separation of compound mixtures, at pressure or under vacuum.
Columns are the core of distillation plants and can be equipped with some different
kinds of internals, depending on application.
• Falling film evaporators/reboilers: they are mostly used for temperature-sensitive
products and are particularly suited to energy saving multiple-effect
evaporation/distillation and mechanical recompression processes due the very small
operating temperature difference.
• Thin film evaporators/reboilers: thanks to the optimal combination of
vacuum/temperature and to the spreading action of the internal rotor, they are
mostly used for extremely high heat-sensitive products and for purification of
substances with very high boiling point.
• Forced circulation evaporators/reboilers: thanks to the high circulation flow-rate
and evaporation external to the heat exchanger, forced circulation technology is the
right solution for streams containing a big amount of suspended solids, fouling
products and for high viscous fluids.
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Oil & Solvent Recovery - References
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Oil & Solvent Recovery - References
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Soil & Sediment Washing
6 - Soil & Sediment Washing
Dredged Sediment Management approach for noncontaminated sediment:
• Maximize Re-use via grain size separation: sand
and gravel recovery (vibro-sieving);
• Achieve silt geotechnical stabilization for Recycle:
• In line Thickening process (centrifuge);
• In line Consolidation process (adding binders);
For contaminated sediment:
• Maximize Re-use via grain size separation: sand
and gravel recovery (vibro-sieving);
• suspension of silt and process water to be sent to
TOP(R) - Wet Oxidation
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6 - Soil & Sediment Washing: recent activities
3V Group is positioned as a unique player to develop
innovative technological solution in a variety of practice
areas at Global Level, thanks to a series of key
partnership with large international contractors in the
infrastructure, municipal, Oil&Gas and environmental
field as:
 TREVI Group: in 2010 3V Group and TREVI started
a close partnership developing environmental
treatment technologies for contaminated soil and
sediments for relevant Italian Port Authorities;
 In July 2014 TREVI Group and 3V Group
incorporated a Company named “6V” which aims
to promote and develop Environmental
Remediation Services at Contaminated Sites
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Research & Development
Research & Development
3V Green Eagle benefits from 3V Group's advanced R&D centers listed below:
1. Mozzo (BG), ITALY. The center is approximately 8.000 m2 large with 4 floors.
2. Grassobbio (BG), ITALY. The center is approximately 300 m2 large and exclusively
dedicated to environmental research.
3. Georgetown (S.C.), USA. The facility is approximately 7,000 m2 large.
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Pilot Plant and Laboratory
3V Green Eagle has become a valuable contributor to the environmental sector. Our principal
company, the 3V Group, has always maintained a strong focus on R&D and in-house
engineering development in the chemical and process equipment fields, allowing some of their
technologies to gain international recognition.
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Ongoing Activities
Ongoing Activities (www.3vgreeneagle.com/en/news)
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For more info please visit our website
WWW.3VGREENEAGLE.COM