Implementation Actions

Action B.1: Construction of the upscaled PNFR system

Next to the CPD optimisation, Front End Engineering Design (FEED) and detailed engineering were performed for the best operating scenario and optimum process configuration. FEED included mechanical and electrical data sheets and preparation of tender packages for the procurement of the main equipment, development of process and instrument diagrams and elaboration of the main piping, instrument and electrical layouts. Moreover, the FEED study considered incorporation of smart meters to the power supply system, to monitor how much electricity the technology was using. An automatic control system of the reactor interfaced with the measuring instruments was also designed to have a view on the relation of the process parameters with the power consumption. The appropriate control points for sampling were also defined. NCSRD proceeded with the construction of the reactor and integration of the photocatalytic membranes and the optical components. Software development allowed control of the reactor and data handling and storage. The preparation of the site and the procurement of consumables and equipment for the integration of the skid mounted reactor with the existing facilities was also implemented in this action.

Deliverables

D-B1.1: Detailed engineering of the PNFR prototype for integration at ZAGORIN

The Implementation Phase of the LIFE PureAgroH2O project included Action B1, focused on constructing the upscaled PNFR system.

In Sub-Action B1.1, detailed engineering design was completed, building on the outputs of the conceptual design (Action A2.1, D-A2.1). The FEED and detailed engineering covered mechanical and electrical data sheets, equipment specifications, tender packages, process and utility piping diagrams, and layouts. Improvements were identified for the internals of the PNFR module based on tests, which were running with the pre-pilot PNFR at the University of Almeria. An automatic control system interfaced with measurements (pressure, flow, temperature, conductivity, turbidity, TOC) was designed to ensure operational stability and analyze process parameters against power consumption. The in-line TOC analyzer was tested for accuracy, and photocatalytic batch experiments with pesticides (Flonicamid, Tebuconazole) were conducted, cross-validating TOC measurements with LC-MS.

The engineering study included piping, instrumentation, stress calculations, and electrical drawings, resulting in 3D blueprints developed in SOLIDWORKS.

In Sub-Action B1.2, procurement of 7-channel ceramic monoliths, chemicals, and photocatalytic membranes was completed, with 80 additional membranes developed. Porous PVDF TiO2 fibers were produced via a dry-wet inversion technique to enhance photocatalytic effects, with about 2,300 meters planned for large reactors, achievable at 2.5 m/min. The irradiation system was assembled using optical components, high-power UV-LEDs, and side-glowing optic fibers, each channel integrated with a fiber powered by LEDs.

A PV system specification was defined to power the prototype’s electrical equipment with renewable energy, aiming to reduce the process’s carbon footprint—expected emissions are slightly higher than current practices, but renewable energy could cut 3.36 tons CO2 annually. Final conclusions will be included in D-C1.3.

For large-scale construction, the .STL files (drawings) of all parts were prepared for CNC manufacturing, moving away from NCSRD’s machine shop. Unlike the skid-mounted small pilot, the large reactors will be installed as autonomous units on platforms designed for easier transport, assembly, and maintenance, with separate skids for pumps and electrical equipment. Software development for process control and data logging was completed on LabVIEW and tested with the small pilot, confirming operability.

Sub-Action B1.3 involved preparing the ZAGORIN site and integrating the reactor. Meetings confirmed that civil works for a new washing/sorting facility (designed for 100 m³/day wastewater) would not interfere with PNFR installation. Although full capacity treatment wasn’t planned within the project timeframe, ZAGORIN will operate the PNFR to treat part of the wastewater, recovering 14.5 m³/day for reuse. Civil engineering for site modifications, including walling and protective structures, has been planned.

Delivery Date: 01/11/2019

D-B1.2: Pilot PNFR prototype commissioned and ready for testing campaign at ZAGORIN

The overall target is to treat and recycle the tail water of a pome fruit sorting/washing/preservation process in the Agrofood industry.

The PNFR unit, the first of its kind, was evaluated for almost two years to validate its performance under actual recycling process water conditions. In addition, the chemical cleaning frequency of the membranes will be determined and will be performed manually when the (Pe) reaches low pre-set values, which depend mostly on the feed water TSS, TS, BOD and COD content. Pe (LMH/bar), is a measure of the flux (LMH) of a fluid through a membrane and is calculated as the ratio between flux and transmembrane pressure (TMP).

The general flowsheet of the overall process is shown in Figure 1, while Figure 2 presents the P&ID diagram of the PNFR process including the sampling points. There are four sampling points related to the performance of the PNFR system (Figure 2). Two of the samples are obtained from the two permeate tanks, each corresponding to the filtrated water of each quartet of PNFR reactors. Another sample is obtained at the water nozzle of the pipeline from the ST to the Feed Tank and corresponds to the feed water and the fourth sample is obtained from the Feed Tank and is a mixture of the Feed Water and the retentate effluent of both quartets of the reactors. Reverting to the overall process (Figure 1), the Sorting/Washing facility is first drained, and the discharged water is conveyed to the CsT tanks. From there, the supernatant RPW water, which is free of coarse solids and mature fine solids, is continuously transferred to the Process Water Tanks (overflow). Next, the Recycle Process Water (RPW water) is subjected to a conventional AC-UVC-H2O2 process, integrating in series, sand filtration/activated carbon filtration/UVC disinfection and H2O2 disinfection, before being collected to the Treated Water Tank and from there recycled back to the Sorting/Washing Process. The PNFR system can operate with two different feedstocks. In the first case RPW is first transferred to the ST tank and subjected to a CFS process using Aluminum sulphate (alum). After drainage of the precipitated fine solids, the pre-treated water is transferred for further purification to the PNFR process. In the second case, the treated water of the AC-UV-H2O2 is conveyed to the ST tank and from there to the PNFR system, but without the need for CFS (this however depends on the condition and maintenance/cleaning programme of these filters). In both cases the permeate of the PNFR is collected to the CWT tank and from there it is recycled back to the Sorting/Washing facility.

Delivery Date: 13/01/2022

Action B.2: PNFR operational procedures for application in ZAGORIN

A safe standard operation procedure in terms of labor and environmental aspects was corroborated for on-site conditions. Start-up testing was performed by NCSRD with the participation of technical staff from ZAGORIN. This encompasses preliminary functionality testing of the system’s individual components and the sub-systems, including electronics. NCSRD prepared the operation, safety and maintenance manual of the overall process and organized training courses at two levels, oriented toward the technical and scientific staff of ZAGORIN. Upon completion of the training activities, extensive testing and operation on-site was implemented, which was of significant importance due to the results validation. These results included the performance of the process in terms of pesticides rejection efficiency, pure water recovery, membrane modules productivity and energy consumption. Moreover, the planned long-term testing ensured reliable results and conclusions on the Life-Cycle of the process, allowing for the definition of maintenance intervals (both for the electromechanical equipment and the photocatalytic membranes) and granting the long-term sustainability of the PNFR process in the FVP industry.

Deliverables

D-B2.1: HAZOP study of the pilot process

The Action included two sub-actions: one assessing the impact of the LIFE PureAgroH2O technology on agri-businesses, and another examining farmers’ attitudes. Conducted in Greece and Spain with tools developed by the Sympraxis Team, the study used a mix of qualitative and quantitative methods.

Key findings showed that water scarcity and the size of agri-businesses influence decisions to invest in wastewater management. Cost, infrastructure compatibility, and access to conventional funding (e.g. low-interest loans) are major factors. Agri-businesses also value low-pollution technologies and actions aligned with the circular economy.

Stakeholder analysis identified agro-industries and water authorities as key players, supported by secondary actors like public bodies and farmers. These were grouped by influence and interest, with strategies developed for each—especially those with the highest potential to drive technology adoption.

A SWOT analysis highlighted strengths like upscaling potential, but also weaknesses such as pre-treatment needs and high operational costs. While climate change and regulation pose threats, opportunities lie in developing low-cost materials and combining technologies for broader application.

Delivery Date: 01/09/2019

D-B2.2: Operation safety and maintenance manual

This manual constitutes Deliverable for the activities conducted in the framework of the implementation action B2, which is related to the PNFR’s operational procedures for application at ZAGORIN. The manual is divided into three sections. The first one pertains to the detailed description of the proper operation of the PNFR process on a daily basis, from the moment when the wastewater effluent is drawn off from the fruit washing baths and collected into the wastewater storage tanks, until the moment when the stored into the clean water tanks, purified water, is reused in the fruit washing/sorting facility of ZAGORIN (a complete daily cycle). The second section describes in detail the maintenance procedures that encompass routine maintenance actions, having as a target to extend the lifetime of the PNFR process, but also maintenance needs and correction actions due to unexpected events. For the latter, significant information is obtained from the HAZOP analysis described in DeliverableB2.1. The third section encompasses solely operational issues which are related to the safety of the process operators. Hence, this section has already been deployed in the HAZOP study (deliverable D-B2.1) which constitutes an attachment to this manual.

Delivery Date: 01/10/2019

D-B2.3: Training of the staff report

During our last two missions at ZAGORIN, (October and April) four people from the staff of ZAGORIN, who are responsible for the operation of the overall pome fruit sorting/washing facility and the AC/UVC/H2O2 cleaning process, were attending in all operations and participated in all activities relevantly to the correction of problems and the startup and first trials of the system. Moreover, they have participated in the sampling procedure and trained on the protocol of sampling

Delivery Date: 31/01/2022

D-B2.4: Report from the pilot campaign at ZAGORIN

Within the scope of the LIFE PureAgroH2O project, ZAGORIN undertook extensive dissemination and stakeholder engagement activities. These included organizing high-level events, such as the 4th Congress on sustainable apple cultivation, participating in international exhibitions such as FOOD EXPO Greece & Cyprus, FRESKON, Agrothessaly, and Panthessalic Multifield Exhibition, and maintaining active communication with local authorities, growers, and industry representatives. Through targeted outreach, media coverage, and collaboration with project Beneficiaries, the Cooperative effectively promoted the project’s objectives in wastewater reuse and environmental protection. ZAGORIN adopted a multi-stakeholder approach for its campaign, which focused on the Cooperative’s vision and targeted various audiences, including consumers, supermarkets, Agri-industry representatives, policymakers, and local growers. The campaign was strategically designed to showcase ZAGORIN’s commitment to environmental protection through a series of interlinked activities. These included the reuse of wastewater, minimizing the carbon footprint associated with apple production and processing, and reducing pesticide use within the framework of the Integrated Pest Management (IPM) scheme implemented by all participating growers.

Delivery Date: 31/12/2024

Action B.3: Analytical procedures

Pesticide residues, their metabolites, heavy metals and physicochemical parameters (e.g. COD, BOD, TSS) were determined in influent and effluent water, from the PNFR unit operating at ZAGORIN, in order to confirm the estimated waste reduction. Pesticide residues and heavy metals were also determined in sewage sludge samples, collected form the washing unit premises. For the quantification of the target analytes, standard and validated analytical methods were applied by using state-of the art analytical instrumentation (LC/MS-MS, ICP-MS).

The total microbiological load (bacterial and fungal) on all wastewater samples was determined to identify possible threats (i.e. human and plant pathogens) for the posterior use/fate of those effluents in field irrigation and/or cleaning purposes at the packaging unit premises. Microbia were determined via classic microbiological (culture-dependent) diagnostic methods, microscopical observation and colony enumeration following standard characterization and quantification protocols.

Acute toxicity assays were performed on wastewater samples using as indicator organisms the crustacean Daphnia magna and the bacterium Vibrio fisheri. In parallel, analytical measurement of the levels of pesticides or other contaminants on the same samples allowed the establishment of correlations between exposure and effects. These results were used for the evaluation of the PNFR for wastewater treatment.

Deliverables

D-B3.1: Report on chemical, toxicological and microbiological analyses of treated wastewater samples from Greece

Part I: Baseline Definition (Pre-PNFR Installation)

  1. Sampling & Monitoring (2018–2019):
  • Four sampling campaigns at 9 points (SP1–SP9) inside and outside ZAGORIN facilities.
  • Water analyzed for physicochemical, microbiological, toxicological, heavy metal, and pesticide parameters.
  1. Findings:
  • Spring water was generally clean, but washing tanks (SP7–SP9) showed high organic load (low DO, high TOC, TSS, turbidity).
  • Elevated levels of metals and pesticides were found, linked to natural sources, apples, or facility materials.
  • Microbial counts were high, especially in wastewater. Chlorination was ineffective.
  • Toxicity was high in wastewater due to pesticide residues.
  • Pesticide presence in sludge was monitored.
  1. Post-Renovation Sampling:
  • A fifth sampling after facility upgrades showed continued microbial and pesticide loads.
  • Specific tanks (SP5–SP9) were identified as critical for monitoring and intervention.

 

Part II: PNFR System Operation

  1. Sampling Points & Monitoring:
  • System monitored across multiple internal points (SP7–SP4) before, during, and after PNFR treatment.
  1. Physicochemical Results:
  • PNFR performance depends on influent quality. Poor pre-treatment (high COD, BOD, TSS) hinders membrane efficiency.
  • Adjustments recommended: improved settling time, online monitoring, and periodic chemical cleaning.
  1. Heavy Metals:
  • Treatment system reduced metal concentrations significantly (up to 84.5% for total metals; 88.3% for Al).
  1. Microbiological Results:
  • Key microorganisms isolated included bacteria and fungi.
  1. Pesticides
  • More than 56% reduction of the pesticide residues

Delivery Date: 31/12/2024

D-B3.2: Report on chemical, toxicological and microbiological analyses of treated wastewater samples from Spain

The company Cítricos del Andarax, located in Almería, Spain, was selected as the target for the implementation of the PNFR. Among the different production lines that are carried out in this industry, gazpacho production was chosen as the most suitable. 

In order to evaluate the characteristics of the water used to wash the vegetables for the production of gazpacho, several sampling campaigns were carried out, in which physicochemical parameters and analysis for heavy metals, pesticides and microorganisms were carried out in order to establish the baseline situation. The results showed that the organic content exceeded the performance limit of the PNFR, for which a maximum COD concentration of 50 mg/L was set. To overcome this problem, different pre-treatments were tested using filtration, pH change and coagulation/flocculation. None of the strategies produced COD results below the proposed limit. 

After that, Cítricos del Andarax installed a new washing system and decontamination premises, which were fully implemented in September 2019. New sampling points were identified, considering both the vegetables washing line and the effluent from the wastewater treatment plant. Washing water was finally not considered due to its high COD levels, despite the application of various pre-treatments based on filtration and coagulation/flocculation. As an alternative point for the implementation of the PNFR, the effluent from the wastewater treatment plant installed in Cítricos del Andarax was chosen as the feed water for the reactor, since it showed COD values below 50 mg/L in the samples taken during the initial evaluation of the new facilities, and there was interest in reusing this reclaimed water for agricultural irrigation. However, the high conductivity of the effluent from Cítricos WWTP was also identified as a problem for the proper operation of the reactor, particularly in relation to the concentration of sulphates and calcium. Mitigation of calcium sulphate scaling is a major challenge in NF and RO processes. The calculated saturation index (SI) is below 1, indicating that scaling may not be occurring, but it should not be forgotten that rejection of the ions during the PNFR process may eventually lead to SI values above 1. In such a case, it may be necessary to adjust the pH of the solution, implement an ion exchange process or even use scale inhibitors.

In addition to the physicochemical characterization of the different sampling points on the old and new facilities, pesticide analyses were carried out to complete the water characterization. Focusing on the new facilities, the total load varied from 7,034 to 12,339 ng/L.

Delivery Date: 31/12/2024

Action B.4: Evaluation and economic analysis of the implementation of the PNFR treatment system

The techno-economic analysis of the PNFR technology itself was implemented via benchmarking with competitive technologies, exploiting the output of the conceptual process design (CPD) studies. The target was to accurately derive the Capital Expenditure (CAPEX) and Operational cost (OPEX) of the PNFR process, and benchmark against state-of-the-art wastewater treatment technologies (BAT) by calculating techno-economic performance data of conventional NF and RO membranes, Activated Carbon, Photocatalysts in powder form and Biocatalysts.

A second activity was to benchmark innovative membranes vs conventional ones. Thus, except for the enhanced performance achieved by the PNFR technology implementing the novel membranes, another target of paramount importance was to define the environmental impact from the production of novel membranes. Life cycle assessment (LCA) was used on this purpose, to characterise “cradle to grave” environmental impacts related with the production phase of the novel membranes. The LCA analysis was performed by NCSRD based on the ISO14040 standard following the Impact Assessment methodology defined by the United Nations Environment Programme and was carried out using the SimaPro 7.0 software.

Deliverables

D-B4.1: Report of the evaluation of Prototype test results with the conventional membranes

To provide a short retrospective summary, at the beginning of the project we faced long delays in acquiring the ceramic nanofiltration monoliths due to repeated international public tenders that have been concluded unproductive. Then we had to address problems and delays in acquiring some important pieces of equipment and assemble the reactors, caused by the COVID pandemic, and subsequently, after installing the prototype system, we had to amend serious technical problems which had raised mainly due to the lack of sufficient time for performing a complete factory testing before the shipment of the reactors and the ancillary units at the facilities of ZAGORIN. Even though the problems had been surpassed thanks to our persistence to make the technology operable and validate it within the course of this project, and sometimes under adverse conditions (Daniel storm), until recently we had not managed to implement a concrete plan of experimental campaigns that would entail the continuous and daily operation of the prototype based on an established protocol of operating procedures.

As such, most of the operation/sampling campaigns performed until the middle of 2024 were inadequate to provide valid conclusions on the performance of the prototype. Despite that these campaigns had been organized after solving the major technical problems, the system was not tested until then under steady operational conditions for more than a couple of hours. Therefore, we ended up collecting samples within a short period of 4-5 hrs, while the system presented new unforeseen technical problems that we were trying to solve on-site, during the sampling campaign. Although these problems were not severe, they didn’t allow us to run the system at full load capacity. Therefore, the results from the analysis of the samples were not appropriate to provide reliable conclusions on the performance of the prototype.

Contrarily, the sampling campaigns by the end of 2024 were conducted under a jointly decided experimental plan, when the prototype had already been tested for many hours and the probability of the occurrence of new unforeseen malfunctions had vanished.

As such, the operation/sampling campaigns of 2024 gave us the opportunity to:

Realize the high variability of the quality of the wastewater fed to the reactor and establish a detailed plan of cleaning and maintenance procedures for the wastewater and clean water tanks, including the sewage system and the ancillary equipment of the PNFR reactor (ducts, pumps, mixing tank). 

Elaborate the capacity of the coagulation/flocculation/sedimentation (CFS) pre-treatment process to bring the wastewater quality to the level (COD, turbidity, suspended solids) required for injection into the PNFR reactor.

Reconsider the need for applying the CFS pretreatment process in case that the COD value is below 30 mg/L, to avoid increase of the Aluminium ion concentration in the clean water effluent of the reactor.

Study the effect of natural organic matter (NOM) on the performance of the prototype to abate the organic micropollutants (pesticides).

Compare the achieved performance to the initially planned KPIs and define the extent of KPIs fulfilment by the performance of the prototype.

Define the required frequency for cleaning the photocatalytic nanofiltration membranes and establish the optimum methodology of cleaning to achieve full recovery of the water flux through the membranes and elimination of the biological load.

Reliably define the operational cost of the PNFR process based on operational facts.

Define technical and operational improvements that could lead to higher performance of the prototype.

Delivery Date: 19/11/2024

D-B4.2: Report of the evaluation of Prototype test results with the novel membranes

Action B4 is one of the most important in this project as it deals with the operation of the pilot PNFR unit and the validation of its performance relative to the capacity of improving the wastewater quality to be reused at the facilities of ZAGORIN. Moreover, this action deals with the economic feasibility of the PNFR process both in terms of operational and capital cost. The action relates to five (5) deliverables. D-B4.1 and B4.2 deal with the evaluation of Prototype test results and the membranes, while deliverables D-B4.3 and B4.4 deal with the techno-economic and LCA analyses from the manufacturing of the novel membranes. Finally, Deliverable D-B4.5 reports on the economic analysis and assessment of the techno-economic impact of the LIFE PureAgroH2O technology in FVP and other industries.

This Deliverable (D4.2) constitutes an updated report relevant to the results presented in Deliverable D4.1. In D4.2 we give a more detailed analysis on the evaluation of the prototype test results with the novel membranes. The analysis encompasses the way we have calculated the performance indicators of the PNFR and the novel membranes, based on the selected sampling points over the entire process, from the source of wastewater (waste tanks) to the clean water tank where the treated water is collected for reuse. The monitored parameters include concentration of hydrogen ions (pH) – 25°C, Electrical Conductivity 20°C, Turbidity,

Total Suspended Solids (103-105°C), Aluminium, Sulphates, Dissolved Oxygen, Biochemical Oxygen Demand (BOD), Chemical Oxygen Demand (COD), Total Organic Carbon (TOC), heavy metals, microorganisms, ecotoxicity and pesticides along with the evolution of water permeability of the novel membranes. 

The target here is not only to conclude on how much these parameters are reduced due to the photocatalytic and rejection performance of the novel membranes but also to draw conclusions on the extent that these parameters affect each other regarding the performance of the membranes. In Deliverable D4.1 our focus was on the results obtained from the last sampling campaign (26-28/09/2024) where we have also evaluated the performance of the membranes against the initial targets e.g. the clean water productivity expressed as the permeability factor, the % abatement efficiency of pesticides and the capacity to recover more than 95% of the wastewater fed to the PNFR reactor.

As an overall output of the 7 sampling campaigns described here (from the installation of the reactor (10/2022) until the summer of 2024 (06/2024)) the novel membranes exhibited satisfactory efficiency in the abatement of the pesticides’ burden. The average efficiency of all sampling campaigns was calculated to be about 58%. When calculating the same efficiency considering also the effect of the carbon filter and the CFS process the number is a bit higher and reaches 60%. The CFS and carbon filter together exhibit a capacity of 54.5%. This concludes to the point that the novel membranes are much more efficient than the carbon filter in the removal of the target compounds from the wastewater. However, under conditions of heavily contaminated wastewater, the application of pre-treatments is mandatory since it assists the reactor to operate fluently while also improving not only the pesticides removal efficiency but also the overall quality of the wastewater relevant to the physicochemical parameters. In specific the novel membranes were very effective in the improvement of the water clarity and the removal of total suspended solids. The average performances in reducing the turbidity and TSS values were 70% and 65% respectively. Moreover, the Aluminium content, which is introduced in the system due to the CFS process, is reduced in the permeate of the novel membranes by 83%. As regards the values of COD, BOD and TOC, there were cases where the efficiency was negligible, but as explained in the following paragraphs, this was attributed to external factors (e.g. contamination of tanks and pipelines) and was not connected with the real efficiency of the PNFR system. As such by averaging the performance values only for the cases where a clear efficiency was observed for the PNFR reactor the obtained numbers are 43%, 31% and 30.1% for COD, BOD and TOC respectively. The PNFR system had also the capacity to reduce the burden of metal ions by 75.8%.

Delivery Date: 31/12/2024

D-B4.3: Report including techno-economic analyses of the manufacture of the novel membranes.

The main goal was to initially elaborate and establish the optimum synthesis protocol for developing the novel photocatalytic ceramic nanofiltration membranes of the LIFE PureAgroH2O project and then to perform the technoeconomic analysis of the membrane manufacturing process. Optimisation was considered in terms of both performance and cost. Regarding the environmental impact, the performed studies and the respective results are thoroughly described in the respective Deliverable (D-B4.4.)

The following described technoeconomic analysis relatively to the manufacturing of the novel membranes is based on data available from two sources. Firstly, from bibliographic sources that describe the procedures, and the raw materials involved for the manufacturing of multichannel ceramic nanofiltration monoliths, and secondly, from the results derived as the output of massive experimentation we have conducted relatively to the methodologies for depositing stable and highly active photocatalytic layers.

Hence in this project, commercial ceramic nanofiltration monoliths were purchased and further used as substrates for the development of the photocatalytic ceramic nanofiltration membranes. In this context, optimisation is considered solely for the latter manufacturing step, where we have applied the slurry coating and the sol-gel dip coating approaches to deposit TiO2 photocatalytic layers on both the shell and lumen surfaces of the ceramic nanofiltration monoliths. The two approaches underwent multiple stages of optimisation for ending up with the final deposition protocol and then compared regarding their cost. The targets of optimisation were to achieve simultaneously:

  • The deposition of photocatalytic layers endowed with enhanced photocatalytic performance.
  • The firm adherence and enhanced stability of the layers.
  • The minimisation of the volumes of the aliquots used in the slurry and sol-gel coating approaches.
  • The minimisation of the waste produced after the coating approaches.

Especially, the two latter targets have significant impact on both the cost of manufacturing and its environmental burden.

It should be noted that in this report, the cost is expressed per square meter (m2) of membrane surface. This facilitates the benchmarking against other types of nanofiltration membranes (e.g. polymeric). However, it is known that ceramic membranes are more expensive than polymeric membranes of the same functionality (e.g., microfiltration, ultrafiltration, nanofiltration), but in view of their long term use, they have the potential to bring significant economic benefits and compensate the cost difference, since they usually exhibit much higher filtrated water productivity as compared to their polymeric analogues, along with extended lifetime (more than 10 yrs compared to 5 yrs for the polymeric membranes). It is also noteworthy that in our procedure, the cost for manufacturing the photocatalytic membranes is added to the cost for manufacturing the substrates, the latter being abstracted from bibliographic resources or taken from the offers we collected from ceramic membrane manufacturers. However, all the offers we have gathered were from European or US manufacturers (Inopor GmbH, Altech GmbH, TAMI Industries, Deltapore Systems BV, Pall Co.). 

Therefore, it is expected that by shifting to international markets for purchasing the ceramic nanofiltration substrates, the overall cost of the LifePureAgroH2O photocatalytic nanofiltration membranes will be significantly attenuated. This is not trivial in our case, since the number of producers of ceramic nanofiltration, and tight ultrafiltration membranes is very limited due to the following reasons:

  • The thickness of the nanofiltration layer is less than 50 nm. The preparation of defect-free membranes is very sensitive and requires a cleanroom facility.
  • The membrane preparation is based on organic solvents (polymeric sol-gel technique). The use of organic solvents in a cleanroom requires specific technical precautions.
  • Defect-free nanofiltration membranes require high quality supports and intermediate layers.

These requirements result in quite high specific membrane costs compared to polymeric nanofiltration membranes. However, as already mentioned, the better performance in terms of flux and lifetime of the ceramic nanofiltration membranes has the potential to level the differences.

Delivery Date: 12/11/2024

D-B4.4: LCA of manufacturing of LIFE PureAgroH2O membranes

The main goal is to quantify the environmental assets of the new photocatalytic ceramic membranes developed in LIFE PureAgroH2O and to verify whether these new photocatalytic ceramic membranes have the same or better environmental performance than the current products that comply with the same functionality (i.e. nanofiltration). It should be stated that the nanofiltration process constitutes half of the functionality of the photocatalytic ceramic membranes of LIFE PureAgroH2O project which are capable of conducting simultaneously nanofiltration and photocatalysis. However, since these membranes are highly innovative and there is no data available for similar developments, we compare our products with products endowed solely with the nanofiltration functionality.

To this end, a life cycle assessment (LCA) of the new photocatalytic membranes has been conducted. The overall assessment throughout the life cycle, considering all environmental aspects, helps to avoid possible hidden environmental aspects or burdens shifting between stages of the life cycle, for instance, geographical region or environmental impacts. It is often the case that improvements targeted at a specific life-cycle stage can adversely affect environmental impacts at other stages of the product (ISO guide 64:2008).

Life Cycle Assessment (LCA) is a widely used standard method (Guinèe, JB. et al., 2002 and Klöpffer, W. et al., 2009). LCA is defined as the “compilation and evaluation of the inputs, outputs of material and energy and the potential environmental impacts of a product system throughout its life cycle” (ISO 14040:2006). The methodology used in LCA studies has been standardized by the International Standardization Organization in ISO 14040-44:2006. It enables complicated products to be analyzed in a systematic way. LCA method is a valuable tool to support decision-making in water treatment in terms of comparison and selection of suitable technologies and to identify opportunities to enhance the environmental performance of the global process (Ribera, 2013).

Our approach is divided into four distinct phases:

  • Goal and scope definition,
  • Life cycle inventory analysis,
  • Life cycle impact assessment, and
  • Life cycle interpretation (ISO 14040:2006).

The scope of an LCA (system boundaries and degree of detail) depends on the goals and intended application of the study. At this stage, the functional unit (FU), which is one of the essential elements to guarantee objective comparisons, must be clearly defined.

The life cycle inventory phase is the collection of the inputs and outputs of material and energy from the system under study. It involves the collection of the data necessary to achieve the defined objectives.

The impact assessment phase consists of relating, quantifying and evaluating the data obtained in the previous stages with selected environmental impact categories to better understand their environmental importance. This phase consists of two fundamental phases: classification and characterization.

Classification is the assignment of the results of the inventory analysis to the selected impact categories under study (e.g. global warming, ozone depletion, etc.).

Characterization involves the conversion of life cycle inventory results to common units and the aggregation of the converted results within the same impact category according to their polluting potential. This conversion uses characterization factors. The outcome of the calculation is a numerical indicator result.

In certain cases, and for sake of facilitating the interpretation of non-experts in the field, it may be interesting to reduce the results of the environmental impacts in a single value with a non-dimensional scale. It is proposed to perform this scaling using the optional elements recognized by ISO 14044:2006: normalization and weighting.

Normalization is the calculation of the magnitude of the category indicator results relative to some reference information with the aim is to understand better the relative magnitude for each indicator result. In this case the relative magnitude that is going to be applied in this study is the EU25+3 region equivalent

Weighting is the process of converting indicator results or the normalized results by using selected weighting factors based on value-choices. In this study, the weighting factors used were obtained by Think step through a survey in Europe.

Due to the enormous amount of data to be processed and the complexity of the data, the development of an LCA requires the use of specific data such as SimaPro or GaBi and the use of associated databases such as ELCD, Ecoinvent or GaBi, among others.

d)The interpretation of the life cycle is the final phase of a LCA, in which the results of the inventory and the impact evaluation are summarized and discussed, assuming the hypotheses and limitations associated with the results and related to the methodology applied, mode of data acquisition, data quality analysis, etc.

Delivery Date: 08/11/2024

D-B4.5: Economic analysis and assessment of the techno-economic impact of the LIFE PureAgroH2O technology in FVP and other industries

Wastewater treatment is an essential process in many industries, particularly in manufacturing, pharmaceuticals, agrifood, chemical production and food and beverage. The adoption of advanced wastewater treatment technologies can significantly impact not only environmental sustainability but also economic performance. This analysis will explore the techno-economic aspects of implementing the novel PNFR technology in an industrial setting. Of course, the technoeconomic assessment will be based on data available from the development, construction, installation and operation phases of the PNFR technology at ZAGORIN. In this respect, since pilot PNFR installed and operated at ZAGORIN is classified as a system of medium capacity (20 m3/day), the output of a technoeconomic analysis at this scale may not be representative of the significant technoeconomic and environmental impacts that can arise from the application of the PNFR technology. We must however note that despite the small size, the investment analysis and final economic feasibility of the current system as reported in Deliverable D-D3.3, have already showcased appreciable economic profits for ZAGORIN and significant environmental impacts in terms of carbon footprint reduction and pesticides abatement. In this analysis, however, we will strive to do a step further and extrapolate the case study of ZAGORIN to a real industrial capacity of 200 m3/day. Therefore, based on the available data, including those of the carbon footprint report (D-C1.3) and LCA and economic analysis of the membranes (D-B4.4, D-B4.3), this report presents the full-scale extrapolation design and the technoeconomic analysis at full scale of the PNFR technology.

The study evaluates the environmental costs and operational sustainability of the system by comparing its performance (emissions, energy consumption, costs) with the previous wastewater management practices. It includes analysis of alternative scenarios for wastewater management, alternative ways for the irradiation of photocatalytic membranes (including direct solar light radiation), assessment of the impact of vis-light catalysts and novel membrane types, and, at the end calculation of direct and indirect emissions across upstream (pre-treatment) and downstream (waste management) processes.

Based on data collected during the LifePureAgroH2O project activities and running of the pilot facility, the following aspects will be evaluated: (i) Efficiency in pesticides abatement, (ii) Wastewater treatment energy demand (iii) Effect of wastewater quality and cost of purification, (iv) Potential for larger scale extrapolation.

The CAPEX will be evaluated considering the constrain/indication of risk management, legislation and standards compliances and data from test run, while OPEX will be based on the evaluation of data from indications from experimental trials, taking also into account the risk analysis which may affect the amount of OPEX.

Delivery Date: 31/12/2024

 

For further information please contact Dr Emilia Markellou (e.markellou@bpi.gr)