Enterprising biosolids pump manufacturers are finding abundant new opportunities in the biosolids segment. With wastewater management becoming a key issue, everyone from truck owners to sludge treatment solution providers is trying to take advantage of the growing biosolids market. While conveyors, trucks and even wheelbarrows can move biosolids through a system, pumps are more efficient and cost-effective. In contrast to conveyors, pumps occupy less space, offer improved cleanliness and worker safety, and require lesser maintenance. Pumps are clear winners for biosolids application.
This article will analyze the various trends and opportunities for pumps in the biosolids market.
Opportunities
Bioenergy
The growing public concern regarding dumping biosolids and increased handling costs are forcing the industrial sector to look at alternatives for productively managing waste. One option is the conversion of biosolids into bioenergy using various techniques such as SlurryCarb (see sidebar), cambi process, gasification and others. Apart from bioenergy, biosolids can be used in alternative technologies such as active sludge pasteurization processes, where biosolids are transformed into high-quality fertilizers. Pumps are an integral part of these systems.
"The biosolids treatment process offers significant opportunity to all the value chain partners including pump manufacturers," says Mike Dillon, president of seepex, Inc. "It is expected that this trend will be more pronounced as an increasing number of firms look toward generating revenues from waste."
Rialto SlurryCarb™ FacilityEnerTech's SlurryCarb process produces a renewable fuel called E-fuel from biosolids. The first commercial SlurryCarb facility was setup in Rialto, Calif. Costing around $160 million, the plant is expected to help recycle biosolids from five municipalities in the Los Angeles region. The plant is likely to process 270,000 wet tons of sludge every year and produce 60,000 tons of e-fuel. E-Fuel will be used by local cement kilns as an environmentally safe alternative for coal. "The customers are looking for long term, sustainable, beneficial reuse of waste, preferably into renewable fuel, and we have to focus on that," says Kevin Bolin, president and chief executive officer of EnerTech Environmental Inc. |
Increasing Adoption by Industrial Users
While the current economic recession has not spared even the biosolids treatment market, the changing market composition is generating hope. Though municipalities have been the main sources of revenue, industrial users are opting for their own treatment facilities due to increasing sludge handling costs. Although the type of treatment facilities depends on regional legislation, they are still opportunities for pump manufacturers. Industrial users range from steel mills and paper mills to food and beverage companies.
Continuous demand industries such as food and beverage are expected to offer significant opportunities despite the recession. One example is the use of potato waste from the processed potato and frozen potato industry. Potato wastewater generated from operations like washing and peeling contains significant amounts of starch. The industrial deep fryers in potato processing plants generate large volumes of waste. This sludge offers potential sources of additional revenue, and an increasing number of firms in food and beverage industry are looking toward productive waste management in the form of bioenergy or as compost for agriculture. This trend is expected to drive the future growth for pump manufacturers.
Demand for Energy Efficiency
One consideration in choosing a biosolids pumping solution is reduced energy consumption levels. With increasing costs of energy, the need to productively manage waste in the most energy efficient way is immensely important. Every dollar saved adds directly to the bottom line and provides major benefits to all the companies and municipalities involved.
End users in food and beverage produce large quantities of sludge. The use of energy efficient systems in these plants will result in lower operating cost, thereby increasing profits. This trend is expected to drive the market toward technologies that will result in potential energy savings for end users.
"Apart from regulations, the need to reduce costs as well as dependence on other energy sources encourages industries to invest in waste to energy conversion solutions," says David Doty, industrial pump sales manager for Moyno, Inc.
Challenges
Customization Requirements
Varying needs of end users demand customized solutions since the pump design changes according to the type of biosolids produced. Even regional regulations can affect the percent of solids in sludge.
"No two cakes are created equal; viscosity and solid content in biosolids largely vary depending on the source. For example, sludge from a paper or carpet mill has more fiber content, making it denser and more viscous than ordinary sanitary sludge," says Dillon.
Customers have the choice to select either progressive cavity or piston pumps. The feeding systems used for the pumps differ based on the type of pump. The efficiency and design of the feed device is a major factor determining the viscosity and solid content of the cakes.
As the application of these pumps differs, the pumping solution should be customized to suit the varying process requirements of the end users. As these projects require huge outlays, any modification after the project has commenced is difficult. This requires the pump manufacturer be highly customer focused and involved early in the process.
"Biosolids pumps need to be customized based on the end user requirement. Our engineers work in close coordination with our customers in designing the pumps," says Mark Yingling, sales manager for Moyno Inc. "Biosolids pump design is a hand science and requires customer centricity."
Piston Pumps versus Progressive Cavity Pumps
There has always been a debate as to which of these two pump types is better suited for a particular application. Piston pumps have been historically used in high pressure biosolids application. A piston pump delivers output at high pressures, thereby enabling the cake to move over longer distances through smaller pipes, while the progressive cavity pump offers a smooth flow. Piston pumps require more maintenance than progressive cavity pumps. As piston pumps are hydraulically driven, energy is lost during the energy transfer from electricity to hydraulic energy and then to the pump. This reduces the efficiency of piston pumps. The lower total cost of ownership resulting from reduced maintenance cost and operating cost has enabled progressive cavity pumps to gradually replace piston pumps.
Reluctance to Pursue New Technologies
Pump manufacturers are constantly trying to improve efficiency and worker safety through new technologies such as automated systems. However, these technologies are often met with limited enthusiasm. Consulting engineering firms and municipalities are often skeptical about new technologies and prefer to use traditional, field proven technologies. As municipalities have been the main sources of revenue for sludge treatment equipment manufacturers, pump manufacturers should work closely with these institutions to help them understand the nuances of these technologies and enable them to appreciate the benefits derived from the application of new technologies. This will aid the pump manufacturers in garnering more market share.
Going Forward
When crude oil prices were high, biodiesel was considered an option to compete with gasoline, so biodiesel plants were commissioned that used biosolids as feedstock. As oil prices started tumbling, these ventures became unprofitable, and the trend slowed.
The biosolids treatment industry is currently facing the challenge of developing an effective, efficient solution to manage waste in a sustainable manner. This offers the potential for innovative companies to develop creative solutions. Though the increasing cost of land application encourages end users to opt for alternative technologies, biosolids pumps manufacturers should strive to be cost effective to gain commercial acceptance. Due to the varying process and technological requirements, pump manufacturers typically work closely with end users to provide customized solutions.
The biosolids ecosystem consists of various participants such as bioenergy firms, dewatering equipment manufacturers, civil engineering firms, municipalities and industrial units. To be more effective, pump manufacturers have to collaborate with other value chain partners to provide solutions customized to specific applications. These solutions would satisfy the varying requirements of the end user and help the companies remain sustainable.
The need for innovative solutions, cost effectiveness, customer centricity and the ability to collaborate with other value chain partners will be the significant factors in the future course of the biosolids pump industry.
Pumps & Systems, October 2009