SEWAGE SLUDGE

1
SEWAGE SLUDGE

PRESERVE
RESOURCES
PROTECT THE
ENVIRONMENT
 HEAT P-
ENERGY FERTILIZER

10-20 %
plant-available
phosphorus

Closing the cycle 4 The systems 12 Your added value 20

Sustainable for the environment 6 References 14 About 22
Approval 8 The path to your PYREG system 16
The process 10 Service 19
4 PYREG ...
D

IS
PO
1

SA
G

L
IN
SEWAGE
CL

3 SLUDGE
UPCY

FERTI-
LIZER
CARBON
CYCLE

2
CARBONIZATION

SS
PROCE
...closes the cycle 5

THE RECYCLING OF SEWAGE SLUDGE IS FACING RISING DEMANDS. CAPACITY BOTTLENECKS, THE UPCOMING PHOSPHORUS
RECYCLING OBLIGATION AND INCREASING ENVIRONMENTAL PROTECTION REQUIREMENTS ARE AMONG THE CHALLENGES YOU FACE.
WE SUPPORT YOU.

UPCYCLING CLIMATE POSITIVE PROCESS DECENTRALISED SYSTEM

THE SLUDGE CARBONIZATE DOES NOT HAVE IMPROVE YOUR CO2 FOOTPRINT AND REDUCTION OF TRANSPORT EFFORT
TO BE REPROCESSED AND CAN BE MARKETED REPUTATION AND COSTS
DIRECTLY AS A PHOSPHORUS FERTILIZER

USABLE WASTE HEAT REDUCTION IN QUANTITY COMPLETE RECYCLING

USE AS AN ADDITIONAL ENERGY SOURCE FOR THE TOTAL QUANTITY OF SLUDGE IS REDUCED THERE ARE NO RESIDUES LEFT TO BE
DRYING PROCESSES BY UP TO 90 % THROUGH CARBONIZATION DISPOSED OF
6 Sustainable for the environment
PYREG SYSTEM: P500

ACTIVE ENVIRONMENTAL PROTECTION ACTIVE RESOURCE PROTECTION SIZE

THE CARBONIZATION PROCESS PHOSPHORUS IS RECOVERED IN
[ m2 ]
COMPLIES WITH CURRENT EU PLANT-AVAILABLE FORM. THANKS TO
ENVIRONMENTAL STANDARDS. GENTLE CARBONIZATION AT LOWER 45
TEMPERATURES (500-700 °C) NO = 3 CAR GARAGE

AFTER-TREATMENT IS NECESSARY.

R BON STORA
CA GE
[ t CO2 ]
per year

440
P1500=1620 T

= 34 HECTARE FOREST
REGENERATIVE HEATING ACTIVE CLIMATE PROTECTION
UP TO 150 KWth OF SURPLUS HEAT ENERGY DURING CARBONIZATION IN THE PYREG
CAN BE SAVED PER SYSTEM AND USED FOR PROCESS, MOST OF THE CARBON
DRYING THE SLUDGE, THUS SUBSTITUTING CONTAINED IN SLUDGE IS STABLY BOUND
TE HEA
FOSSILE ENERGY CARRIERS. AND DOES NOT ENTER THE ATMOSPHERE WAS T

AS CO2. AS A FERTILIZER SUBSTRATE IN [ kWh ]

P1500=1620 T

per year
THE SOIL, CARBON IS REMOVED FROM THE
CYCLE FOR CENTURIES.
1,125,000
= 45 HOUSEHOLDS
FEWER TRANSPORT MEANS LOWER COSTS AND LOWER CO2 EMISSIONS
7

SEWAGE SLUDGE SEWAGE SLUDGE

4 % DS* DEWATERED WITH 25 % DS*

SEWAGE SLUDGE
DRIED WITH 80 % DS*

SEWAGE SLUDGE
AS PYREG® PHOSPHORUS FERTILIZER

Additional CO2
sequestration
by using as
* DS = dry substance
fertilizer
 PLAY
8

IT SAFE
 9

2018 2019 FUTURE

The phosphorus fertilizer, which is obtained by using With the newly enacted EU regulation of March 29th, Switzerland and Germany have already introduced
the PYREG process, can be registered as an inorganic 2019, the phosphorus fertilizer is now available a P-recycling obligation. Other countries will follow.
fertilizer for the first time in Sweden on September throughout the EU and finally also in Germany (EU PYREG offers you today a future-proof and environ-
27 , 2018 (PYREGPhos, KEMI no: 5164115262).
th
Regulation 764/2008 on the free movement of goods mentally friendly treatment of sewage sludge includ-
& EU 2019/515 on the mutual recognition of goods). ing phosphorus recycling.
10 PYREG process

150
SUPERIOR PHOSPHORUS
NO PROBLEMATIC SUBSTANCES USABLE HEAT ENERGY
QUALITY

The PYREG process is a continuous method and uses The process gas, generated in the PYREG reactors, is
the principle of dried carbonization. For that purpose, cleaned from dust by an automated process gas filter
the dried sewage sludge is guided through PYREG- and completely burned by the FLOX-burner (flame-

kWth
reactors operated at a temperature of 500 - 700 °C. less oxidation) at temperature of 1,000 °C inside a
In the PYREG reactors the sludge is not burned, but separate combustion chamber. This way, thermal
carefully degassed and then carbonized, by admis- NOx is significantly avoided. The formation of prob-
sion of a tightly targeted air stream. This way the ma- lematic substances like oils or tar is suppressed as
terial is completely sanitized. well, because the process gas is not cooled, but oxi-
dized in the combustion chamber.
Due to the selected temperature level in the PYREG
The carbonization process is self-sustaining; after-
reactors the phosphorus in the final product grants a Inside a flue gas cleaning system, harmful acidic
completion of the activation phase no further external
high plant availability (in contrast to ashes). Supple- components are absorbed by means of alkaline flue
energy is required to run the process, as the energy
mentary costly pulping of the phosphorus is not gas scrubbers, whereas volatile components like
of the sludge is sufficient for the continuance of the
necessary. mercury are retained by activated carbon filters.
thermal treatment. It is even possible to benefit from
the excess heat produced; an amount of 150 kWth may
be used for sludge drying.
Detailversion für Klärschlamm-Anlagen mit Abgasreinigung, EN

HEAT

11

Receiver tank

INPUT W
Exhaust gas heat Wet scrubber Activated Exhaust gas fan Chimney
exchanger carbon filter

Process gas filter

PYREG -reactor
®

FLOX®-burner

Rotary wheel sluice

Slag pot

Combustion air

Conditioning

OUTPUT
12 PYREG systems

P500 P1500*
COMPACT AND DECENTRALIZED

PYREG plants are compact, container based and can Size l 9,000 mm l 12,000 mm
w 3,000 mm w 3,000 mm
easily be integrated into an existing infrastructure
h 5,800 mm h 5,800 mm
and material cycles. Our plants for sewage sludge
recycling and for gentle phosphorus recovery have Combustible rating 500 kW 1,500 kW
been proving their worth since 2015 and have been
Annual throughput approx. 1,100 t per year approx. 3,200 t per year
installed at 4 sewage treatment plants in Germany, DS, dry substance

USA and Sweden.

Yearly production approx. 610 t approx. 1,760 t

Please note: The adjacent system data are model val- Excess thermal energy approx. 150 kWth approx. 600 kWth
ues to give you an initial idea. Exact system data can
Operation hours per year approx. 7,500 h/a approx. 7,500 h/a
only be determined together with you, after a detailed
analysis of the location, available infrastructures, Power consumption approx. 12 kWel approx. 25 kWel
sludge and a material test. Please feel free to contact Additional l 6,000 mm l 9,000 mm
us for a discussion. technology module w 3,000 mm w 3,000 mm
with flue gas cleaning h 2,800 mm h 5,800 mm
system (flue gas
scrubbers, activated
carbon filters)

Based on 25 % DS sewage sludge, (dried > 11 MJ/kg OS) *in planning

 Quality of your sludge 13

REQUIREMENTS FOR SAFE AND ECONOMICAL TREATMENT USING THE PYREG PROCESS

ANALYSIS BASIC CONDITIONS

Obviously, every sludge is different. Only on the basis

of an individual sludge analysis can we make an ini-
tial assessment and make statements as to whether
your sewage sludge is suitable as a fertilizer sub- POURABLE

80%
strate. AND FREE APPROX.
FLOWING

The focus is on
MIN.
CALORIFIC

10
MIN. CONTENT OF DRY
Available annual quantity VALUE SUBSTANCE
Heavy metal and pollutant contents

Organic dry matter content

MJ/kg
Existing or necessary sewage sludge treatment
technology such as dewatering or drying TOTAL
VOLUME
OF MIN.
1,000 T (DS)
PER YEAR
14

PYREG
SYSTEMS
IN OPER-
ATION
22 Biomass systems
6 Sewage sludge systems
FURTHER PLANTS
2 Activated carbon systems

GER Entsorgungsverband Saar (EVS) P500 in operation since 2016 4 Laboratory systems

SWE Skanefro SE P500 in operation since 2019

GER Abwasserverband Main-Taunus P750 in operation since 2020
CZE City of Trutnov P500 in operation since 2020
 15

WWTP LINZ-UNKEL, GERMANY WWTP SILICON VALLEY CLEAN WATER, USA

OPERATOR: Zweckverband Abwasserbeseitigung Linz-Unkel OPERATOR: Bioforcetech Corporation

LOCATION: Unkel (near Bonn), Germany LOCATION: Redwood, California, USA

SEWAGE PLANT SIZE: 30,000 p.e. (population equivalent) SEWAGE PLANT SIZE: 200,000 p.e. (population equivalent)

PYREG SYSTEM OPERATION SINCE 2015: P500 PYREG SYSTEM IN OPERATION SINCE 2017: P500

SLUDGE TREATMENT: SLUDGE TREATMENT:

Sludge stabilization (2-stage compact digestion) Drying of the sludge

(75 % volume reduction with 60 % lower energy consumption)
Dewatering and drying
(60 % reduction in quantity; required energy is completely covered by Carbonization of sludge with a P500 system
the thermal energy of the PYREG plant and micro gas turbine) (approx. 90 % volume reduction; required process energy is
completely self generated; additional excess thermal energy is used
Carbonization of sludge with a P500 system for the drying process)
(approx. 90 % volume reduction; required process energy is
completely self generated; additional excess thermal energy is used Sludge carbonizate is marketed directly to the agricultural sector as
for the drying process) a natural soil improver.

Europe-wide approval of sludge carbonizate as fertilizer

16 The path to your PYREG system

ANALYSIS LOCATION PLANNING AUTHORITIES APPROVAL

We analyse your recycling We analyse the structural Draft planning and EIA Coordination of a preliminary We accompany you through
problem: Is carbonization conditions: Even at this early screening: On the basis of design with the competent the approval process and
worthwhile for you? We will stage, we check the licensing a careful site analysis, we authorities: We create the prepare the necessary plant
help you to find an answer to conditions on site. design the most suitable basis for the approval and and process data for you.
this question. We evaluate the plant for your operation. On construction of the plant. We
quantity and quality of your request, we can also configure coordinate the draft with the
sludge and give you a realistic any additional equipment you employees of the responsible
assessment so that you can may need, such as drying, offices.
make a safe decision. dewatering, power generation,
etc., and plan the necessary
infrastructure and technical
interfaces with you.
 17

PRODUCTION &
DETAILS ASSEMBLY ACCEPTANCE SERVICE MAINTENANCE
The detailed planning of the We keep you fully informed Acceptance and commissio- We monitor the operation of Plant maintenance ma-
plant begins: The individual about the individual pro- ning: We organise the official your plant online. nagement: We develop an
modules are manufactured duction steps. As a plant acceptance of the finished Around the clock. individual maintenance plan
and the plant is going to be manufacturer, we have been plant, commission the plant for your plant and implement
built. developing and manufacturing and support you during the it on request with our on-site
high-quality carbonization running-in process. service and in-house service
plants in tested quality and personnel.
„Made in Germany“ at our
company facilities in Dörth for
more than 10 years.
18
 Service 19

OUR EXPERIENCE ADDITIONAL SERVICES ON-SITE SERVICE

As a company for mechanical engineering and envi- To ensure that the PYREG technology fits optimally Once your PYREG system is up and running, you also
ronmental technology, we are active in the develop- into your recycling cycles, we offer you a wide range benefit from our comprehensive support. This in-
ment and manufacturing of compact carbonization of optional additional services. This includes, for ex- cludes remote monitoring and diagnosis as well as
systems in proven quality for more than 10 years. Our ample, a selection of different conveyor technology, on-site service from our technicians.
PYREG systems are used worldwide. storage technology and integration into the heat con-
cept at the site.
20 Added value

E
ET
PLM
CO
L NATURE CLIMATE
RA
NT
CE
DE

PHOSPHORUS FERTILIZER
FE
SA

CARBONIZATION

SEWAGE SLUDGE
 21

VALUE PROPOSITION. BENEFIT FROM THE MARKET LEADER.

PURCHASE OPERATOR MODEL* MARKETING

WE PUT TOGETHER A TAILOR-MADE YOU ONLY PAY FOR THE USE OF OUR WITH OUR PARTNER COMPANY NOVOCARBO,
INVESTMENT SOLUTION FOR YOU AND HELP TECHNOLOGY. THE OPERATING COMPANY WE DETERMINE THE MARKETING POTENTIAL
YOU WITH FINANCING NEGOTIATIONS WITH IS RESPONSIBLE FOR THE OPERATIONAL OF YOUR BIOCHAR AND TAKE OVER THIS
THE BANK. READINESS. THE COSTS ARE EXACTLY PROCESS STEP FOR YOU.
CALCULABLE.

PRODUCT DEVELOPMENT PREMIUM PRODUCTS ACTIVE PARTICIPATION

WE DEVELOP A SYSTEM BASED ON CUSTOMER ONLY HIGH-QUALITY CARBON PRODUCTS IN INTERNATIONAL RESEARCH PROJECTS
NEEDS, LEGAL RECYCLING REQUIREMENTS AT ATTRACTIVE PRICES ARE IN LONG-TERM IN THE AGRICULTURAL, MUNICIPAL AND
AND CO2 BINDING CONCEPTS. DEMAND ON THE MARKET INDUSTRIAL SECTORS.

*For large companies and municipalities

22 About

MARKET LEADER AWARDED EXPERIENCED

Thanks to permanent innovation and further tech- Winner of Success-Technology award, innovation Proven method: More than 30 units are currently in
nical development, PYREG meanwhile has turned award of Rhineland Palatinate, inventor award of service worldwide.
out to be one of the most important pioneers in Rhineland Palatinate … Worldwide presence: D/A/CH-region, USA, China,
environmental technology. Particularly in the sector Nominated for Diesel Medal, Start-Green-Award, Sweden, Belgium, Czech Republic, …
of phosphorous recycling from sewage sludge and Energy-Award, … Clientele in several sectors: Municipal companies,
the resulting production of valuable biochar, feeding Technology supplier for winners of Bloomberg manufacturers of compost and garden soil,
char and activated carbon, we are one of the market Philanthropies Majors Challenge (Stockholm), agricultural enterprises, recycling companies,
leaders worldwide. winner of Austrian Climate Protection Award (Gerald WWTPs, food and pharmaceutical industry as
Dunst) … well as waste management companies make use of
our systems.
2011 until today
made in germany
Entry of further shareholders (state of
Rhineland-Palatinate, German Startup Group,
ELIQUO WATER GROUP/SKion, Abacus Alpha/KSB,
Hevella Capital)

2010
Entry of PYREG Beteiligungsgesellschaft and
establishment of PYREG GmbH in
Dörth/Rhineland-Palatinate

2009
Spin-off of PYREG GmbH from the joint
research project

2007 - 2010
Operation of a PYREG plant prototype at the
wastewater treatment plant of the AVUS Ingelheim

1999 - 2009
Dipl.-Ing. Helmut Gerber and Prof. Dr.-Ing.
Winfried Sehn develop the PYREG process at the
University of Applied Sciences Bingen
24

PYREG GmbH
Trinkbornstr. 15-17
56281 Dörth
Germany
Phone +49.6747.9 53 88 0
info@[Link]

[Link]

sludge_brochure.EN.12.2019