Abstract of Deliverable 1.3.
REPORT ON WATER INNOVATIONS IN THE PIPELINE
1. Emerging techniques from BREF
Food & drink sector:
No emerging techniques referring to use of water or waste water treatment are addressed in
BREF for Food, Drink and Milk Industries and BREF Slaughters house and animals by-products
industries.
Pulp & paper sector:
This BREF covers the processes involved in the production of pulp and paper in integrated pulp
and paper mills as well as for non-integrated pulp mills (market pulp) and non-integrated
papermills using purchased pulp for paper production. The main operations covered are:

chemical pulping

kraft (sulphate) pulping

sulphite pulping

mechanical and chemi-mechanical pulping

recovered paper processing with and without de-inking

papermaking and related processes
For several chapters, emerging techniques are presented:
 The KRAFT sulphate pulping process, “Removal of Chelating agents by modest alkaline
biological treatment or by use of kidneys”: The chelating agents EDTA and DTPA has been
used for many years in the pulp and paper industry These metal ions are able to catalyse
the decomposition of the bleaching agent hydrogen peroxide into radicals. Totally chlorine
free (TCF) bleaching is currently only possible by treating the pulp with Chelating agents
before the hydrogen peroxide stage. Although EDTA is non-toxic to mammals at
environmental concentrations, there is some concern about the potential of EDTA to
remobilize toxic heavy metals out of sediments and the difficulties to biodegrade this
substance.
Biological treatment with and without activated sludge systems commonly used in the pulp
and paper industry is successful in reducing COD and BOD of the effluents. However, the
system can not significantly reduce EDTA of the mill effluent. It has been found that EDTA is
resistant to aerobic biodegradation in the activated sludge plant operated under "normal"
1
conditions (pH 7). Furthermore, EDTA does not adsorb onto sludge so that EDTA passes
through treatment plants without notable degradation. A recent study [Virtapohja, 1997]
investigated the biodegradation of EDTA in a full-scale activated sludge plant under modest
alkaline conditions (pH 8 - 9). An average EDTA reduction of about 50% (about 10% at pH 7)
was obtained. Another technical option to reduce the consumption and discharge of chelants
used before the peroxide stages in TCF mills is the use of kidneys. In the Netfloc system
[Rampotas, 1996] the pH is increased and carbonate dosed for precipitation. Metals bound
to EDTA (or DTPA) are released and precipitated. The biodegradation of EDTA in activated
sludge plants under alkaline condition looks promising.
Environmental implications: In a full-scale activated sludge plant under modest alkaline
conditions (pH 8 - 9) an average EDTA reduction of about 50% (about 10% at pH 7) was
obtained. The results also indicated that the pH adjustment to 8 - 9 with calcium oxide
(dosage about 90 mg CaO/l) did not interfere with the normal operation of the activated
sludge plant. Concentrations of EDTA in the samples with accelerated biodegradation
remained relatively constant (2 - 4 ppm). Biodegradation of EDTA increases the release of
nitrogen. Enhanced degradation of EDTA in activated sludge plants is therefore of clear
benefit, not only for environmental reasons but also as a means to increase the level of
nutrient nitrogen, which usually is deficient in wastewaters from pulp and paper mills.
Economic considerations: Additional costs for the biodegradation of EDTA in activated
sludge plants under alkaline conditions are primarily caused by the CaO consumption. For
the application of the Kemira NetFloc system no data on economics are available.
 Mechanical pulping and chemi-mechanical pulping, use of new evaporation techniques as
“kidney” for internal cleaning of process water: In mechanical pulping most of the organic
material released during production comes from a few sources. Currently, in most mills
wastewater treatment is done together for all mill effluents, which is a purposeful way to
achieve a stable operation in the biological treatment. Recently, a few mills introduced new
concepts, which focus on internal treatment of most concentrated or problematic partial
wastewater streams by other techniques. Thus, it is tried to separate contaminants closer to
their place of origin to decrease the size of the water treatment equipment needed. In
principal, to reduce the amount of contaminants, micro-flotation, membrane filtration,
chemical oxidation, evaporation and combinations of these techniques could be used.
Energy consumption and investment and operating costs in the given application will have a
crucial influence on the choice of treatment system. For mechanical pulp and paper mills
multi-effect vacuum evaporation seems to be especially promising because sufficient
amounts of waste heat is available to operate the treatment system.
2
Environmental implications: This new application of advanced wastewater techniques
opens the door to significant reductions in effluent volumes and loads to recipient.
Economic considerations: Modern techniques for internal cleaning and reuse of process
waters can be as cost effective as traditional wastewater purification (biological
treatmentHowever, whether this technique can be economically justified depends on the
specific conditions of the given mill.
 Recovered paper processing, Advanced effluent treatment with a combined process of
ozonation and fixed bed biofilm reactors: Secondary treatment of wastewater from paper
mills is applied in numerous mills in Europe thus reducing emissions to water significantly.
Advanced treatment of remaining pollutants after biological treatment is aiming at a further
reduction of COD, AOX, colour and other matters. Effective advanced effluent treatment unless partial flows can be successfully pre-treated – is normally downstream the biological
stage. A treatment process was developed during the last five years to improve the treated
effluent quality in view to stronger environmental regulations and the possibility for the reuse
of treated effluent in the process. This tertiary effluent treatment consists of a combination of
ozone with fixed bed biofilm reactors and results in a significant elimination of COD, colour
and AOX with a minimum of ozone dosage. The treated effluent has a low content of
disturbing matters so that the reuse of tertiary treated effluent in the process seems to be an
interesting option. That means, the ozone treated water can be either discharged or re-used
in production. The chemical analyse of tertiary treated effluents shows that apart from the
elimination of organic matter (measured as COD) other substances are also drastically
reduced or eliminated such as colour, AOX, heavily degradable optical brighteners and
chelating agents, bacteria and spores. The process can be considered as in a developed
stage.
Environmental implications: The efficiency of ozone treatment depends strongly on the
quality of the individual water to be treated and the specific lay out of the treatment system.
Therefore, no general statement on the achievable environmental performance is possible.
In effluents meeting certain boundary conditions in terms of COD and BOD5/COD ratios, the
bioavailability can be enhanced to allow additional biological treatment. The ozone treated
water can then be either discharged or re-used in production. The main focus of this process
however is the transfer of persistent organic compounds (residual COD, AOX, and colour)
into biodegradable fractions (only partial oxidation i.e. limited and controlled oxidation of
organic carbons). This results in a significant increase of the BOD/COD- ratio. The results of
3
pilot tests with paper mill effluents after biological treatment show that further COD removal
efficiencies up to 90 % (referred to COD concentration after secondary clarifier) can be
achieved with specific ozone consumption of 0.7 - 1.0 kg O3/kg COD eliminated after the
biofilters. Removal efficiencies of about 50% or more are achieved by one-stage ozonationbiofiltration. COD removal efficiencies of well above 50 % up to 90 % are achieved when the
process is operated in two stages. After the first ozonation stage a biofilter degrades partially
oxidised organic matter. The second stage consists of another ozonation step followed by a
biofilter. This process lay out avoids full oxidation of organic matter by ozonation thus
reducing the amount of required ozone and optimising the operation costs. The target of this
lay out is not to consume ozone for readily biodegradable matter. With the exception of the
small amount of biological excess sludge produced in the biofilters polluting substances are
really eliminated and not only separated. Therefore, this treatment does not generate a
concentrate that calls for further treatment, as it is the case when membranes or evaporation
are used.Negative cross-media effects are energy consumption for ozone .
 Recovered paper processing, membrane bioreactor for end-of-pipe or (partly) in-line
treatment: membrane bioreactors (MBR) are combined separation-oxidation processes.
They have two main functions: 1) Enhanced biological oxidation (decomposition of organic
material). Enhanced because the conditions in a membrane bioreactor are such as to
encourage biomass adaptation (long sludge age and absolute retention of biomass (no
clarifier acting as a biomass selector). 2) Separation of solids and liquid by use of a
membrane process. The membranes are immersed directly into the biomass of the activated
sludge plant and operated at very low transmembrane pressures (0.2 bar typically). The first
full-scale application went into operation in 1999 at a French cardboard mill (Papeterie du
Rhin). In the case of this cardboard mill the sludge will be reinjected in the pulper.
Environmental implications: For some types of mills, which could not meet discharge limits
an MBR could allow them to reach their discharge limits. But the process could also be used
as pre-treatment for downstream separation/concentration processes such as nano-filtration
(NF) or evaporation. This application might be interesting for operators of paper mills who
think to use MBRs in their mill-water circuit closure plans, allowing e.g. to use cheaper NF
configurations and to meet more stableoperating conditions. Membrane bioreactors can
produce a lot less sludge (up to half) than a conventional biological treatment, because of
the specific characteristics of the active biomass growing in those MBR applications.
 Recovered paper processing, "Kidney" treatment - Techniques for further circuit water
cleaning: A low wastewater load can be achieved by a combination of a suitably designed
4
process water system and internal wastewater purification. Process water in the paper
industry is used for a number of different applications, with different water quality
requirements. Hydraulic separation of different process units creates relatively small internal
water circuits, which can be treated more efficient. Water circuit closure is currently restricted
by various contaminants (disturbing substances) in the process water, which have a
disruptive effect on either the technology or the product. Separation of process units from
each other (e.g. by use of thickeners) makes it possible to remove disturbing substances
inside the process unit in which they are generated in order to prevent contaminants
travelling through the whole papermaking process. The contaminants in the separated water
loops can be (partial) removed from the water circuit in question to a desired level, in order to
fulfil the process water quality requirements set for that specific process unit. This approach
results in complex concepts that require a lot of knowledge for control of the system.
There are basic differences between the furnish, technologies and requirements of finished
paper depending on whether graphic grades ("white grades") or packaging papers ("brown
grades") are involved. In principle, the configuration of systems for packing papers is always
simpler than for white grades. For brown grades manufactured from recycled fibres it is
possible to control completely closed circuits by integrating a biological treatment stage (see
Section 5.3.4). There are even paper mills that manufacture brown grades operating with
closed water systems (zero emissions to water) without internal treatment. With "white"
graphic papers, the wastewater load can be minimised by internal treatment of process
water by use of membrane filtration, ozonation plus biofilter or alternatively by evaporation
technology, so-called "kidney" treatment. However, the suitability of such technologies in
continuous operation needs to be carefully tested before they are put into industrial
production. These techniques can also be applied as advanced external treatment following
common biological treatment. Advanced treatment of partial flows of process water ask for
treatment and water management methods that are not yet spread in paper mills. However,
a lot of development works for treatment of process waters has been carried out in most
European countries.
Environmental implications: The recycling of treated water reduces the consumption of
fresh water and also the volume of effluents. By selecting the most appropriate partial
process water flow for the internal treatment it is possible to reduce the total discharge to
water. However, the impact of closed water circulation on the energy and material balance of
the whole mill should always be carefully assessed. In some cases the internal water
treatment concept ("kidney strategy") can lead to better efficiencies for the whole mill.
5
 Paper making and related process, minimum effluent paper mills - optimised design of water
loops and advanced wastewater treatment technologies: Advanced wastewater treatment in
pulp and paper industry is mainly focused on additional biological- membrane-reactors,
membrane filtration techniques such as micro-, ultra or nano-filtration, ozone treatment and
evaporation. Due to relatively less full-scale experience, sometimes relatively high costs and
increased complexity of the water treatment, there are only a few full-scale applications of
tertiary treatment of wastewater mill effluent up to now. However, these techniques
especially have a potential to be applied as in-line treatment as
so-called "kidneys" to
eliminate well aimed those substances that negatively interfere with the efficiency of paper
production or paper quality. An example is how to appliy a combination of membrane
filtration, ozonation and evaporation for process waer treatmente in a paper mill. However,
the choice andarrangement of the kidneys in the production process has to be determined
case by case. Some of these techniques are only applied in pilot-scale. Full-scale
experiences in paper mills are limited to a few examples in the world. Depending on the
technique applied there are still operation problems and relatively high costs.
Environmental implications: The objective of advanced waste/process water treatment
technologies is usually to further remove pollutants that are not removed by common
biological treatment as for instance by use of activated sludge plants. Those pollutants are
residual COD, colour, nutrients or suspended solids. Advanced water treatment processes
produce a high water quality. As a consequence there is a better chance to re-use the
"effluent" in the process as fresh water. Thus, advanced wastewater treatment can
contribute to further water system closure. However, it can also be applied to achieve lower
discharge loads to the recipient.
Reference literature:
ftp://ftp.jrc.es/pub/eippcb/doc/ppm_bref_1201.pdf
[Edelmann, 1999], [Gartz, 1996], [Gartz, 1998], [Wigsten, 1995], [Legnerfält, 1997]
[Öller, 1997 a +b], [Möbius, 1997 a], [Möbius, 1999], [Helble, 1999],[Kaindl, 1999]
[Borschke, 1997], [Proceedings, 1997 a]
[Edelmann, 1997], [Borschke, 1997]
6
2. Water innovations in the pipeline in UK, NL, CY, DK and SP for the INNOWATER focus
sector
7
2.1 FOOD & DRINK
Technology
Sector
Name innovation
(product/ service)
Innovation
stage
Short description
What is new?
Cost and/or Environmental
aspects
UNITED KINGDOM
Food &
drink
**Optimisation of MBR
Technology
For example: Optimal aeration
for membrane bioreactor (MBR)
technologies1
Understanding the Activated
Sludge Process and MBR in
relation to metal contamination;
Cranfield University ‘The fate of
metals in wastewater treatment’2
Also development of alternative
membranes, and combination
with other processes such as
advanced oxidation – see below.
See also Denitrification above.
** Potential for application in
Chemical sector
1
2
3
Lab-based
research
through to
market
introduction
Membrane bioreactors (MBR)
combine activated sludge
treatment with a membrane
liquid-solid separation process.
The membrane component uses
low pressure microfiltration or
ultra filtration membranes and
eliminates the need for
clarification and tertiary filtration.
The technology permits
bioreactor operation with
considerably higher mixed liquor
suspended solids (MLSS)
concentration than conventional
activated sludge systems, which
are limited by sludge settling.
 Developments to reduce
operating costs
 Improved performance for
removal of organic
contaminants
 Removal of specific
contaminants, e.g. colour
from textile dye
 Design of multi-modular, and
hybrid units to treat a
combination of contaminants
For example, the optimal
aeration project at Cranfield
University is seeking optimal
aeration for MBR technologies
in order to reduce OPEX costs
(primarily associated with
membrane replacement and
energy demand).
Understanding the Fate of
Heavy Metals defined the
MBRs generally considered more
efficient than activated sludge process
(but currently more expensive).
Environmental benefits are complex: e.g.
increasing aeration reduces opex but
may be associated with an increase in
capex.
The small footprint of MBR systems, and
the high quality effluent produced, make
them particularly useful for water reuse
applications.3
http://www.cranfield.ac.uk/SAS/water/ research/researchareas/page39445.html
http://www.cranfield.ac.uk/SAS/water/research/researchareas/page39479.html
http://en.wikipedia.org/wiki/Sewage_treatment
8
impact of key operating
parameters, such as the mixed
liquor suspended solids
(MLSS) concentration, and
introduction of typical ancillary
streams, such as the return
sludge liquors on the removal
of metals during ASP and
MBR processes.
4
5
Production of Activated Carbon
from Sewage Sludge
Imperial College, London4
Lab-based
research
Municipal and industrial
wastewater treatment plants
produce large volumes of
sludges, and their processing and
disposal is a complex problem in
the field of wastewater treatment.
One interesting option is the
production of activated carbon
adsorbents/catalysts from
sewage sludge.
The specific objectives of the
project are to produce and
characterise sludge-based
adsorbents/catalysts under
different experimental
conditions, and to establish
cause-effect relationships
between the characteristics of
sludge-based adsorbents and
the performance in different
wastewater treatment
applications. The project
formed part of an EU funded
research programme called
‘Reduction, Modification and
Valorisation of Sludge’.
Improvement of sludge processing and
disposal
Biological and Microbial fuel
cells
For example, Newcastle
University,5’Development of a
potential energy self sufficient
Lab-based
research
Biofuel cells use bacteria to
convert the chemical energy of a
particular substrate to electrical
energy. This is achieved when
the bacteria pass electron energy
At Newcastle University,
research is currently focused
on developing novel low cost,
biological and microbial fuel
cells, specifically to:
The direct generation of electricity as a bi
product of wastewater treatment and cost
savings in wastewater treatment by
eliminating aeration costs.
http://www3.imperial.ac.uk/ewre/research/currentresearch/drinkingwaterandwastewatercontaminantsandtreatmenttechnologi
http://www.ncl.ac.uk/ceam/research/natural/projects.htm
9
process to treat waste and
waste water using Microbial Fuel
Cell’; ‘Biological and Microbial
Fuel Cells’ Also Edinburgh
University.
Wastewater Tertiary Treatment
using Renewable Energy Crops
‘Water Renew’6 project: WRc, in
partnership with Cranfield and
Queens Universities and the
Department of Agriculture and
Rural Development Northern
Ireland
6
Pilot
on to an electrode rather than an
electron acceptor (such as
oxygen or nitrate). If that
substrate is a waste, then that
waste can be converted into
electricity.
A basic biofuel cell can operate in
two ways. It can use biological
catalysts - enzymes extracted
from biological systems - to
oxidise fuel molecules at the
anode and to enhance oxygen
reduction at the cathode of the
biofuel cell. Alternatively, whole
microbial cells can be used to
supply the biofuel cells with the
fuel.
 increase the power density
by enhanced
bioelectrocatalysis
 simplify fuel cell design and
application with low cost
high performance materials
 identify and ultimately
design appropriate microbial
communities for bio-fuel
cells
Using a crop management
scheme with willow / poplar /
eucalyptus under short rotation
management, and fast growing
grasses e.g. Miscanthus, there is
potential to demonstrate a system
which offers integrated benefits of
a low energy, wastewater tertiary
treatment, with the production of
a renewable bioenergy crop.
System uses pre-treated
wastewater to irrigate crops,
which are subsequently used in
AD.
The project team will build
upon crop research and recent
international research (notably
in Sweden / Australia), to bring
Water Renew systems to
commercial application in the
UK.
 A cost-effective, low energy,
sustainable system to treat wastewater
by removing nitrogen and phosphorus
 Financial and environmental benefits
through generating energy by-products
with reduced greenhouse gas
emissions.
http://www.waterportfolio.com//asp/project_information.asp?project_id=257&status=Ongoing
10
Fluidised bed reactors (FBRs)
and Expanded bed reactors
(EBRs)
For example:
Advanced Bioprocess
Development7
Lab-based
research to
market
introduction
A high load anaerobic wastewater
treatment system, in which a
faster rate of upward-flow velocity
is designed for the wastewater
passing through the sludge bed.
The increased flux permits partial
expansion (fluidisation) of the
granular sludge bed, improving
wastewater-sludge contact as
well as enhancing segregation of
small inactive suspended particle
from the sludge bed.
Advanced Bioprocess
Development (ABD) is a spinout from Manchester
Metropolitan University that
designs and optimizes
biological wastewater
treatment processes for
licensing or under contract,
based on expanded bed
technology. The company
typically achieves 30-40 kg
biomass per m3 of expanded
bed, which is at least 10-times
the concentration that can be
achieved with continuous
processes using suspended
cells.
According to ABD, their large surface
area results in low-cost, compact
processes, which can double the
efficiency of oxygen transfer and thus
reduce energy consumption by 30%.
Cleaning in Place (CIP)
For example:
Whirlwind System ®
Lab-based
research to
market
introduction
CIP is a method of cleaning the
interior surfaces of pipes, vessels,
process equipment, filters and
associated fittings, without
disassembly. Since the 1950s,
CIP has evolved to include fully
automated systems with
programmable logic controllers,
multiple balance tanks, sensors,
valves, heat exchangers, data
acquisition and specially
designed spray nozzle systems.
Whirlwind System is a unique
High product recovery during
the pipe cleaning phase. A
fraction of the amount of water
used compared with traditional
CIP. Minimal wastewater and
chemical usage and so
significantly reduced effluent
discharge. Change over time
reduced as pipework can be
quickly dried and made ready
for reuse.
Significant financial saving for customers.
Highly positive impact on key factors
such as water use, chemical use,
discharge costs.
11
patented system for clearing,
cleaning and drying processing
pipework using vortex airflow
technology
THE NETHERLANDS
Food &
drink
Purill, infrared disinfection for the
food industry
Pilot scale
testing
http://www.watertechnologie.co
m
Disinfection technology based
upon infrared technology, which
is also direct applicable on the
food (e.a. potatoes and
vegetables) itself. Compared to
UV the infrared light could be
placed outside of a tube, enabling
a more flexible use.
An incremental innovation, due
to the fact that an existing
technology; infrared light is
used for a new purpose;
disinfection of water and food.
Compared to UV, the energy saving is
approximately 90% and the lifetime of
infrared lights is at least 10 times higher
than conventional UV lights. These
factors substantially reduce operational
costs for the water treatment operations
within the food & beverage industry
Compared with chlorination there is an
enormous reduction of discharge of
aggressive pollutants that could enter the
surface water.
DANA (Dynamic Anaerobic
Aerobic process) (*)
http://www.watertechnologie.co
m
Full scale
testing
A Dutch consortium combined
different technologies that use
aerobic treatment for communal
and industrial waste water (e.a.
Moving Bed Reactor). The
challenge is to re-engineer the
technology for industrial use with
anaerobic applications.
Two existing technology are
combined in one a tank where
the anaerobic water after
purification through an
automatic process control by
an aerobic purification. A
scoop is the high efficiency
plastic carrier medium for the
aerobic purification Aqwise
apply for the anaerobic
purification.
The DANA system makes a 30-40%
reduction in investment compared to
established separate processes.
Additionally halving the saving of space
which is partly due to process
simplification and associated cost
savings in equipment and software.
12
OptiCIP+; development of an
inline cleaning optimization
system in the dairy industry
Full scale
testing
Food manufacturers are willing to
take the safe side when it comes
to hygiene. Therefore, many
machines and often cleaned. But
water, cleaning products and
machines that stop for cleaning,
cost money. Efficiency is
warranted. Therefore the
OptiCIP+ is devised, a system
that provides optimum cleaning.
The regular way of cleaning in
the food industry, focused on
the worst-case scenario and
Cleaning in Place (CIP), is
changed by the system. The
OptiCIP+ uses in-line
monitoring and control devises
to regulate the cleaning
process. The system
measures the pollution load
and provides information on
the appropriate cleaning time
and duration.
Savings detergents (caustic, acid,
EDTA), saving rinse water (10-20%) and
discharge polluted detergent (2500 ton),
reduced gas consumption (10-20%).
Pilot scale
testing
To meet the increasing energy
demand, new renewable energy
sources must be found. One is
anaerobic wastewater treatment
(or hypoxic) industrial bioreactors,
which is made through
fermentation of biogas. A Dutch
consortia created an innovation to
increase the efficiency of biogas
reactors.
Currently online monitoring
and guidance are lacking in
biological process in
bioreactors to increase the
efficiency. With the innovation;
a microchip capillary
electrophoresis online
monitoring will be possible
within 5 minutes compared to
the conventional half a day
regular laboratories need.
If the results of the testes are positive, an
online sensor system could be put on the
market, which enables the industry to
increase the efficiency of its bioreactors
with up to 25% more biogas.
Operational
A Dutch producer of cheese and
whey powder invested in a water
treatment system, which enables
the company to close the water
cycle and establish a full water
recycle system.
The company used to buy
water from the regional
drinking water company, but
with the new system they
recycle their water. The water
use is also minimizes as much
as possible throughout the
Traditional dairy companies produce 1
liter of waste water for every liter of
processed milk, with this system the
company reduced their waste water load
to 0,6 liter and will even work towards a
waste water load of 0,4 liter for each liter
of milk. This makes a reduction of
http://ec.europa.eu/environment/l
ife
Qwatch: Biogas reactors online
monitoring and control
http://www.senternovem.nl/water
technologie
On-site water treatment and
water cycle closure in a cheese
factory
http://ec.europa.eu/environment/l
ife
The payback period for the system, due
to savings is estimate on: 1.5 - 3 years.
13
factory while using the sytem.
environmental contamination possible.
The company will not generate direct
profit from the system, due to the fact that
the return on investment time is as long
as the lifespan of the system; 10 years. It
does reduce the investment costs.
ANPHOS®; environmentalfriendly phosphate removal in
anaerobic effluent by means of
struvite process
Market
introduction
A Dutch potato-processing
company, has developed a
wastewater treatment system that
converts phosphates into
fertiliser. This is referred to as the
ANPHOS® method. This
environmentally friendly method
is used to convert phosphate from
wastewater into usable artificial
fertiliser. It might sound easy, but
it was preceded by a huge
amount of research. Reason
being that wastewater is
characterized by the complexity
of the material.
This system uses magnesium
salts instead of iron salts or
aluminium salts. Magnesium
salts are less expensive and
have a low environmental
impact. During processing,
phosphates and ammonium
are converted into magnesium
ammonium phosphate
(MgNH4PO4), otherwise
referred to as struvite.
Pilot
During wine production, large
volumes of both liquid and solid
waste are produced, the quantity
and quality of which depend on
the wine type and the production
techniques.
Most Cypriot wineries do not
have biological treatment
plants in place. Even though
the relevant legislation exists,
a large number of wineries still
spread their effluents in fields
http://ec.europa.eu/environment/l
ife
The residual product can be used as
fertiliser or can be added to various
fertilisers. An additional environmental
advantage is that less sludge is
produced. This sludge is also of a higher
quality. Moreover, far less energy is
needed for the aeration of the aerobic
treatment process. The system functions
at 200 m3/hour and to full satisfaction
CYPRUS
Food &
drink
Advanced systems for the
enhancement of the
environmental performance of
WINEries in Cyprus - LIFE08
ENV/CY/000455WINECEnvironment Policy &
Specifically the project shall:
Conduct an analysis of the European and
Cypriot wine industries, as well as of EU
and local statutory provisions relating to
the operation of wineries, and identify
14
Governance projects selected
in 2008
Wastewater originates from
various washing steps during the
crushing and pressing of grapes,
and the rinsing of fermentation
tanks, barrels and other items of
equipment.
Wastewater quantity and quality
shows seasonal variations, with
the peak wastewater generation
occurring when grapes are
actively being processed into
juice for fermentation.
Total wastewater production of a
winery is estimated to be 1.2
times greater than the production
of wine. Solid waste, including
skins, stems, pips, lees and
sludge, is also produced. Both
winery wastewater and solid
waste need to be managed
appropriately prior to their final
disposal in fields or receiving
water bodies.
without any treatment,
therefore polluting
groundwater resources.
Consortia between Danish micro
breweries and knowledge
providers on the improvement on
hygiene and water use.
A general update of CIP
procedures makes it possible
to reuse water and to update
the hygiene thereby increasing
The program will help
investigate and development
of advanced systems for the
enhancement of the
environmental performance of
WINEries in Cyprus
good practice examples;
Conduct an environmental analysis for
wineries in Cyprus;
Conduct a detailed environmental review
for the Tsiakkas Winery;
Set up an environmental policy for the
Tsiakkas Winery and establish an EMS;
Design, develop and construct a pilot
Winery Wastewater Treatment (WWWT)
plant;
Develop mechanisms for frequent
internal control and reporting of the
winery’s environmental performance,
including the operation of the WWWT;
Suggest solutions to overcome any
constraints identified during the
establishment of the EMS and WWWT;
Develop a good practice guide for the
improvement of the environmental
performance of wineries, and
specifications for WWWT plants, to be
disseminated to a number of
stakeholders, including wineries,
wastewater engineering companies,
environmental consultants and public
authorities.
DENMARK
Food &
drink
Hygiene, water and sanitation in
micro breweries
Demonstration/
development


Better product
Lower water use
15
the quality of the product.
At line monitoring of bacteria
Demonstration/
research
In recirculated aquaculture the
production of geosmin gives the
fish an earthy taste. A fast
detection of the geosmin
producing bacteria will reduce this
problem. In many sectors
different bacteria are a large
problem for the production. The
current project aims at making it
possible to fast identify the
bacteria and from there identify a
solution. The projects works in
three different industries;
aquaculture, oil drilling and
wastewater treatment
The system is based on
Fluorescent In-Situ
Hybridization, a system
currently available in microbial
laboratories.
Application of Membrane
treatment ( UF, reverse
osmosis, nanofiltration, etc…)
www.Aquaespana.org
Already in the
market
Uses of membrane filtration
system of different molecular cut
sizes, depending on the quality of
water delivered.
Allows for different qualities of
water for reuse in the
processes of the company.



Better product
Less use of chemicals
Better food safety
SPAIN
Food &
drink
Different Purified water qualities
according to the treatment of membranes
applied.
Allows the reuse of water, save on water
unnecessary.
Manuel Gonzalo.
www.mebreraes.cm
System MBR
It requires a greater energy cost than
conventional treatments such as
coagulation-flocculation.
Already in the
In an MBR system technology for
Not required after disinfection
High cost
16
market
National Center for Food Safety
and Security (CNTA)
www.cnta.es
Waste water reuse techniques
Already in the
market
National Center for Food Safety
and Security (CNTA)
www.cnta.es
the biological treatment with
activated sludge is combined with
sludge microfiltration membranes
by replacing the traditional
decanters secondaries.
treatments.
Increase the capacity of the
filter and allows control of
sludge age.
Application of tertiary treatment to
wastewater previously purified to
increase water quality and new
uses give residual water.
Reuse of treated water in other
parts of the process according
to the quality of water obtained
Water consum reduction.
Low waste generation, high quality of the
discharge purified by this system allow
the use of treated water reuse systems.
Sometimes it does not require vast
investments to increase the quality of
water, just a sand filter + disinfection
later.
Advanced oxidation processes
treatment with Ozone
Chemical Engineering University
of Alcalá de Henares.
Already in the
market
It is based on the application of
ozone and germicidal oxidizing
capacity and as a disinfectant of
wastewater.
Shortly contact
No hazardous waste is
generated
+ Effective than chlorine
treatments
Shortly contact
No waste produced.
More complex technology than
chlorination.
High costs in terms of investment and
demand for electrical energy
Advanced oxidation processes
treatment with UV
Already in the
market
Using UV radiation as a
disinfectant in wastewater
treatment
High disinfection power,
eliminates the occurrence of
trihalomethanes as disinfection
byproducts, kills
microorganisms such as
Cryptosporidium and Gandia.
No byproducts selective.
Short exposure times.
Not altered properties of acute
Constant water quality.
Few waste.
www.Wedecorex.com
Ramiro cercós Coullaut
Tratamientos de oxidación
avanzada Sistemas FENTOM
FMC Foret.
Section of Chemical
Already in the
market
It is based on the oxidation of
organic molecules in aqueous
solution by adding a soluble iron
catalyst in water and hydrogen
The installation requires minimal
operation and maintenance
requirements.
Simplicity of treatment.
Non-toxic waste.
17
Engineering, Universidad
Autonoma de Madrid
peroxide
High efficiency of treatment.
Set performance at any time and get a
constant water quality from effluent
entering irregular composition.
sonia.blasco@uam.es
Usage of new cleaning solutions
in just one time to clean CIP
system in milk industry.
Spanish BAT guide for milk
sector
Although there
have been
testing this
technique in
the dairy sector
in Spain, the
results have
not been
consistent.
Is the replacement of traditional
detergents used
CIP cleanings sequentially (acids,
bases, disinfectants) by
detergents "one
pass "getting the same results but
with lower water consumption
and products
detergents.
New cleaning techniques that
save water use.
The environmental benefits can be seen
with the program of cleaning with a
detergent of a pass requires less stages
rinsing and application of product.
Another environmental advantage of
these systems is the lower content of
nutrients that
cause water pollution such as
phosphorus and nitrogen.
the cost of the products of a single pass
are high compared with those
traditionally used in the industry.
Ozonated water use in the
disinfection stage of C IP
systems.
Spanish BAT guide for milk
sector
is being tested
in other
agro-industry
sectors with
positive results
As / alternative to the use of
chemicals at the stage of
CIP cleaning disinfecting
proposes the use of ozonated
water.
ozonized water is a powerful
oxidant that in addition to
disinfecting, oxidizes organic
matter
residual.
Since ozone is an unstable
molecule that is transformed in a
New cleaning techniques that
save water .
Reducing water consumption by
eliminating the rinse
final and volume of sewage. Elimination
of toxicity associated with products
chemicals.
18
short time
oxygen, no rinsing is necessary
for disposal later., also the
ozonized water can be used
again in first rinse of next
cleaning cycle.
Combined Physical Bare
Spanish BAT guide for
vegetable processed sector.
Scalded using MICROWAVE
Spanish BAT guide for
vegetable processed sector
Under
investigation,
pilot
the aim of the research being is
the replacement of chemical
peeling by a combination of
physical treatments
(Pressure, vacuum, steam,
friction, ultrasonic ,...) so that
appropriate performance and
quality and cost competitive.
The advantages of using
combined physical methods
against chemical peeling can
summarized as follows:
�Less water consumption
�
� Eliminates the use of
polluting chemical reagents
Disadvantages:
organic solid waste generation (remains
of raw material)
and possibly the economic costs.
Pilot
The main difference between
traditional blanching and
microwave blanching is to be
used
radiation heating of the product,
rather than by convection and / or
driving.
Microwave introduction in
Industry.
One advantage of microwave blanching
is that heating takes place throughout the
volume of the plant, instead of driving
surface heating and subsequent outsidein that is given conventional treatment.
This means lower operating times In
addition, noconsume water resources so
that almost no discharges are generated
in this operation.
Energy use is more rational to be applied
directly on raw materials, while the
conventional blanching energy is lost in
heat exchanges are required to reach the
product.
High energy consumption , high
instalation costs.
19
Scalding using steam
in the operation of scalded by
immersion, hot tubs consume
large amounts of water and
energy. An alternative to this
technique is scalding steam,
where the birds hung on hooks, is
passed through a tunnel which
steam is applied.
New scalding procedures
No technique is
implanted
steaming by
economic
constraints
involved.
Cooking in a steam oven
generates much less sewage that
cooking in hot water baths, which
is considered as traditional
Kilns of meat products using
water vapor as the fluid to drive
heat
New cooking techniques.
minimize the generation of wastewater in
this operation.
As well there is no substance
solubilization of the product, the organic
load associated with them also
decreases. reduction of volume and
pollutant load cooking water (75% water
saving).
currently there
are
technical
limitations for
the application
of this
technique,
since the
materials
packages do
not provide the
desired quality
baked goods.
cooking the meat pieces is an
operation that provides a high
pollutant load to the cooking
water if appropriate measures are
taken.
This technique is to cook the
product in a plastic container
suitable for processing
heat but prevents the transfer of
substances of the product water.
New cooking techniques.
This way hanging the water becomes
less frequent, thus reducing their
consumption, wastewater generation and
energy consumption. The energy
consumption reduced because less water
must be heated and because it lowers
the waste water treatment
Environmental improvement: obtained
improvements in consumption water and
wastewater.
Spanish BAT guide for meat
sector.
Steam cooking ovens
Spanish BAT guide for meat
sector.
Cooking parts already packed
BAT guide for meat sector.
reduces energy and water consumption
25% comparing the technique with
scalding steam from scalding dive.
There are limitations techniques for
applying this technique The bird feathers
provide insulation against steamed.
obtained improvements in consumption
water and wastewater generation, as the
pollution generated by the product
20
(Organic matter, salt) is greatly reduced.
Energy consumption decreases
for the least amount of water to be
heated and the lower volume and
pollutant load
the wastewater to be treated.
21
2.3 PULP & PAPER
Technology
Sector
Name innovation
(product/ service)
Innovation
stage
Cost and/or Environmental
aspects
Short description
What is new?
Full scale
testing
A catalyst with string technology
is used a transmitter for high
frequent vibrations to influence
the cristal structure of calcium in
water to reduce scaling effects on
tubes and possible membranes.
A radical innovation of a totally
new technology for the water
business. It is quite uncommon
to use high frequent vibrations
for water treatment.
Calcium removal by pH change,
combined with sedimentation/separation
is common technology. With this
innovation an environmental benefit is
ensured due to a significant reduction of
chemicals
Market
introduction
A different approach to water-air
mixing as a means to clean
strainers and felts in the paper
industry. Instead of internal or
end-of-pipe mixing, external
mixing is applied to reduce the
water use within the cleaning
process.
A new way of implementing
water-air mixture with pressure
to increase cleaning capacity
of nozzles.
The water saving with nozzle technology
makes a water reduction of 90% percent
in the nozzle possible.
By use of a combination of
innovative techniques, it was
demonstrated in full size that it is
possible to recycle high-quality
wastewater in the photo, film and
Incremental innovation, using
existing techniques and
combine them, creating an
innovative process for
recycling and water saving.
THE NETHERLANDS
Pulp &
paper
String Energy; water treatment
with high frequent vibrations
www.watertechnologie.com
Applying water-saving nozzle
technology serving screening
and felt conditioning in the paper
industry
http://www.senternovem.nl/water
technologie
High quality water recycling for
photo, film and paper industries
http://ec.europa.eu/environment/
life
Full scale
testing
With the water-air mixing, the momentum
of the water beam can be retained (and
hence the cleaning capacity), reducing
the use of fresh water. At a pressure of
<6 bar a 50% water saving is possible.
Using the new plant, sludge production is
reduced by at least half the previous
amount, which has resulted in reduced
transport and processing costs for the
company.
22
paper industries. The techniques
used to do this are a membrane
bioreactor and reverse osmosis.
The innovation also enables a reduction
of the amount of Chemical Oxygen
Demand (COD), silver and chemicals in
the waste water, which benefits the
environment.
DENMARK
Pulp &
paper
Colloid chemistry in industry
Development
Research
project: PAKK
Application of advanced colloid
chemistry in the industry to
update separation and
flocculation.
Separation is a withal part of
many treatment technologies.
The consortia focused on
improving the separation by
introduction of advanced
colloid methods in industry
(wastewater treatment, food,
paper and medical)




Optimization of doses on
chemical coagulant.
Already in the
market
Use of new polymer coagulants in
appropriate doses, rather than
the iron salts used so far.
New polymers that helps on
physico-Chemical treatment.
More effective dosification.
Dosing reduction.
Better separation
Higher water reuse
Lower cost for separation
Decreased expenses to chemicals
SPAIN
Pulp &
paper
Department of Chemical
Engineering. F: CC. Chemistry.
Universidad Complutense de
Madrid. Madrid 28040.
ablanco@quim.ucm.es
Dept. of Development. Holmen
23
Paper Madrid. C / The Role 1.
Polígono Industrial La
Cantueña, Fuenlabrada 28946.
ignacio.sanpio@holmenpaper.c
om
Microflotación of particles
techniques.
Department of Chemical
Engineering. F: CC. Chemistry.
Universidad Complutense de
Madrid. Madrid 28040
ablanco@quim.ucm.es
Under
investigation
Very small air bubbles are
injected directly on the liquid
phase through diffusers and help
small solid particles to float on the
surface.
It allows to eliminate better
and faster the small and light
particles.
Once the particles are on the
surface can be obtained by
surface scratching
Faster than decantation.
Sludge more compacted.
Dept. of Development. Holmen
Paper Madrid. C / The Role 1.
Polígono Industrial La
Cantueña, Fuenlabrada 28946.
ignacio.sanpio@holmenpaper.c
om
24
3. General conclusions on innovative developments in
the INNOWATER countries
Food & drink sector:
Among the proposed innovations that have been listed in this document, most of them consist,
mainly, on progress or optimization of existing technologies. For example, most countries seem
to be working on improving technology to minimize CIP water consumption and / or affection of
the wastewater generated in the cleaning process. Similarly, most of them also work on
optimizing technologies about anaerobic or aerobic digestion of waste water, and technologies
about disinfection with lower environmental affections.
Arguably, the innovations proposed by Cyprus are aimed to analyze the situation of water use in
that country in the food sector, while in Spain are more aimed to minimizing water consumption
and waste water. Meanwhile, the Netherlands seem to be working in all the processes that
make up the water cycle in the food sector, while the United Kingdom seems more focused on
technologies to minimize the impact of discharges. Regarding the UK, the study and
development of new technologies that allow the use of sewage sludge for the production of
activated carbon or electric power generation must be highlighted. Finally, DK is working in
detection of the geosmin producing bacteria, in order to get better products, and reduce the use
of chemicals.
Pulp & paper sector:
Another sector that consume great quantity of water is pulp and paper sector, into this sector in
BREF we could find lots of innovative technologies but most of them are based on membrane
system combined with some desinfection treatment of effluent, in a great quantity of mills
depending on the production process of paper we can find waste water treatment with a
physico- chemical treatment so the optimization of coagulants doses are an innovative and
saving cost technique.
In the paper sector the best technologies are directed to the optimization of water consumption
by closing circuits (close water loops) which can be reached by an adequate management and
the application of treatment techniques and reuses. This includes internal circuit closing (in
paper manufacturing processes) and re-use of these waters, as well as the final spill recycling
once it has been treated.
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