We set new standards: SynGas, the patented, technologically sophisticated SÜLZLE KOPF process uses dried sewage directly on site to produce energy and heat. Locally – directly on the sewage treatment plant premises This reduces not only the characteristic pollutant levels, but also saves transport costs while freeing up recyclable resources that you can use or sell. This makes your business sustainable and economical.
A sector with a future - Utilising sewage sludge
The purification of waste water in mechanical-biological sewage treatment plants generates large amounts of residual sewage sludge. In Germany, the more than 10,000 municipal sewage treatment plants have to dispose of approx. 2 million t/a dried sewage sludge matter (TS). Due to increasingly rigorous waste water directives and the corresponding intensification of sewage treatment processes, the amount of generated sewage sludge is expected to increase in the medium and long term. What is more, the progressive sealing of the landscape will also contribute to the collection of larger amounts of waste water and thus to a higher incidence of sewage sludge.
New general regulations
The German directive for settlement waste (TASI) states that the direct depositing of untreated sewage sludge is no longer permitted on landfill sites. In many areas, the application of sewage sludge to soil has been prohibited or officially declared a discontinued model by the government.
High pollutant loads
In future, the phosphorus recovery directive will prohibit co-incineration with other sewage to support decentralised thermal single treatment plants.
Sewage sludge contains various pathogens, such as worm eggs, bacteria, viruses and prions, along with hormones that may affect the endocrine system. During decomposition in the sewage treatment plant, the thermally resistant pathogens remain intact along with the remaining toxic elements.
The spread of such a cocktail in the environment was the primary cause for the BSE virus. The effects of many of the substances contained in sewage sludge on the ecosystem are not known.
Resources made available
There is no alternative to the thermal treatment of sewage sludge. However, sewage sludge also contains recyclable resources. SynGas offers you a method that removes the harmful substances while making resources available. The sewage sludge is utilised directly, without any transport that would damage the environment, and produces electricity, heat and ashes.
Source: Statistisches Bundesamt (Federal Statistics Office), Wiesbaden, Germany 2013
Utilisation of recyclable resources
The gas is used to generate energy and heat in a thermal power station. After a holding time of approximately 30 minutes in the reactor, the sewage sludge also yields an inert granulate with a high phosphorus content that can be extracted. This granulate can be processed into fertilisers to replace phosphorous minerals with a local secondary raw material.
The process produces a mineral granulate that can be utilised in various applications as an aggregate for producing asphalt and as a fill material in road construction and civil engineering.
Syngas: Everything from a single source
From the initial concept, to all planning and implementation phases, through to commissioning: Together with our experts, we are at your side helping you to realise your SynGas gasification plant. Benefit from our expertise and many years of experience! Working together, we will find the optimal solution for you. And after the project is completed, we will keep your plant running with long-term maintenance. Safe, profitable, sustainable.
Description of the KOPF SynGas utilisation process
Due to the many difficult substances such as bacteria, medication, sulphur, heavy metals – the KOPF SynGas Process is based on a two-stage thermal treatment. In combination with multi-stage, downstream purification, this results in clear synthesis gas for use in a combined heat and power plant (CHP).
Two-Stage Thermal Treatment
Sewage sludge (dry content 85-95%) is conveyed from the silo (1), together with limestone (2), to a thermolysis screw feeder (3). The products, thermolysis gas, carbon and ash, generated during thermolysis, are conveyed to a fluidized-bed gasifier (4).
In the second stage of gasification, the carbon is converted unter substoichiometric conditions into gas and the long-chain molecules (so-called tar) of the thermolysis gas are cracked. The granulated ash is discharged into an ash silo (5).
In the cyclone (6), the raw gas is freed from dust in a coarse filter and cooled to 400°C in the recuperator (7). In the process, the air is preheated for the gasifier. The fine dust is separated in a candle filter (8).
The quench (9) cools the gas to 35°C with treated waste water. The remaining dust and tar are separated. After recirculation in the centrifugal washer, the quench water is purified in a subsequent water treatment process.
In the centrifugal washer (10) the aerosols generated in the quench column are removed. The acidic washer (11) serves to remove the nitrogen compounds in the gas.
Three activated carbon filters follow. The first one (12) removes the mercury with iodized activated carbon and via adsorption. The second filter (13) removes any remaining H2S with special activated carbon. The “police filter” (14) removes the remaining aromatic hydrocarbons.