a resource efficient and clean alternative to direct land application Jo Van Caneghem, Carlo Vandecasteele

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1 Electricity it from poultry manure: a resource efficient and clean alternative to direct land application Pieter Billen, José Costa, Pieter Billen, José Costa, Jo Van Caneghem, Carlo Vandecasteele

2 NL: 100 M hens per year Poultry farming 1.5 Mt/y poultry manure Total manure production: 71 Mt/y Supply > Demand Excessive fertilization Nitrate directive (91/676/EEC) and national legislation Compare 1. land spreading, use it directly as fertiliser 2. combustion to generate electricity PRO SAAMYA,INC, 2013 Source: CBS, PBL, Wageningen UR (2012)

3 CO 2 Land spreading N 2 O NH 3 pathogens PO 3 4 NO 3 NH 4 +

4 Poultry litter combustion Average Std. Dev. Moisture wt% Ash wt% DM C wt% DM H wt% DM N wt% DM S wt% DM Cl wt% DM Ca wt% ash Mg wt% ash K wt% ash Na wt% ash P wt% ash Poultry litter: LHV = 7.2 MJ/kg Adapted from: Consonni, S. Energy potential of waste. Athens, 19 june 2012

5 440 kt / year BMC Moerdijk (FBC for poultry manure) ca. 600 farmers contracted 31 MW e net (70000 households) turbine 60 kt ash / year fuel bunker ESP stack BFBC energy recovery lime baghouse SCR

6 Is combustion cleaner sustainable production? UNEP: RECP (Resource Efficient and Cleaner Production) Advance Production efficiency optimize use of natural resources (materials, energy, water) Environmental management minimize adverse impacts on nature and the environment Humandevelopment minimize risks to people and communties, support their development

7 Sustainable energy production and GHG emissions Electricity production Net 31 MW e, η net =28% 1 ton of poultry litter replaces about 200 kg coal, avoids 425 kg of emitted CO 2 eq. Biogenic Land application GHGs GHGs Energy content is lost No electricity produced CO 2 CO 2 CO: negligible CO: negligible N 2 O: kg CO 2 eq. per t N 2 O: kg CO 2 eq. per t Indirect: Transport Flue gas heating (SCR) Lime and NH 3 production Indirect: Transport (unknown)

8 Sustainable energy production and GHG emissions ure 400 Combustion Land spreading per ton of poultry man equivalents kg of CO N 2 O Avoided Emissions Lime NH 3 SCR gas heating Transport Min. Max. Min. Max.

9 Optimise use of materials Dry flue gas cleaning (no water needed) Ash (bottom ash, boiler ash, flyash and APC residue) used as fertilizer/soil amendment No pathogens No NH 3 emissions Odorless and dry, ensuring easyhandling and transportation

10 Ash composition Use of materials (combined bottomash ash, boiler ash, fly ash and APC residue) Specification Composition wt% DM CaO 21 K 2 O >11 12 Na 2 O 1.1 MgO > P 2 O 5 >10 12 SO Cl 2.0 De facto PK fertilizer, but low P solubility upgrade opportunities wt% DM P 2 O 5 sol. in water 0.06 P 2 O 5 sol. in neutral ammonium citrate t P 2 O 5 sol. in 2% citric acid 8.5 wt% DM K 2 O sol. in water 11 K 2 O sol. in neutral ammonium citrate 12 K 2 O sol. in 2% citric acid 12 Balance the nutrient supply and demand of regions

11 Use of materials P Excess P Excess N P P Low P Excess N Low P Excess N Low P Excess N

12 Minimization of impacts on the environment Electricity production from fossil fuels is replaced BMC emissions Emissions for fossil fuel + (kg/ton wet poultry manure combusted) CO 2, fossil CO NO x NH SO HCl PCDD/Fs < to produce same amount of electricity as produced from 1 ton of wet poultry manure (NL) less emissions to the environment, except NH 3

13 Minimization of risks to people All heavy metals in ash below limit for land application (combined dbottom ash, boiler ash, fly ash and APC residue) Limit Composition mg/kg DM Al As 5 <3.0 Cd Co Cr Cu Hg 1 <0.05 Mn Ni Pb Zn

14 Minimization of risks to people Based on the K 2 O/P 2 O 5 application rate, the amount of HM spread on land is identical for ash and for manure Pathogens destructed Limited formation of PCDD/Fs, due to low Cl of poultry manure low HM concentration in ash (catalyst)

15 Community development Sustainable demand for manure is offered to contracted farmers Contribution to regional employment Direct: ca. 30 jobs mainly for technically skilled persons Indirect: transport, ash upgrading

16 Use of ash Biogenic CO 2 Conclusion: RECP Valorization of energy content Production efficiency protective use of natural resources (materials, energy, water) No water use Employment Environmental management minimize adverse impacts on nature and the environment Humandevelopment minimize risks to people and communties, support their development Lower NH 3 emissions than land spreading Emissions < or comparable to other energy plants HM spreading identical Destruction of pathogens

17 Agglomeration in bed due to low melting salts in the ash Eg E.g. K 2 Si 4 O 9 (770 C) C), KPO 3 (810 C), Eutectics: lower T m Technological issue Consequence: Defluidization (few times a year) downtime, cleaning of installation Availability < 90%

18 Ahf Ash formation Research Mechanism 1 Reactions in bed ash Thermodynamics Melting Phase diagrams Agglomeration Roedder (1959)

19 Research Mechanism 2 Ash formation Melting of ash Agglomeration Reaction with bed ash Solidify + CaO Solid material KH 2 PO 4 (s) KH 2 PO 4 (l) H 2 O (g) + KPO 3 (l) Ca 3 (PO 4 ) 2 (s) + K 2 O

20 Research Variations of the fuel Layer hens Broiler hens Ash [wt% DM] Al [mg/kg DM] K [mg/kg DM] Na [mg/kg DM] Ca [mg/kg DM] Si [mg/kg DM] Mg [mg/kg DM] Fe [mg/kg DM] 1100 n.r. 1 P [mg/kg DM] Source: ECN Phyllis 2 Database Countermeasure: addition of CaCO 3

21 References Van Caneghem, J., Brems, A., Lievens, P., Block, C., Billen, P., Vermeulen, I., Dewil, R., Baeyens, J., Vandecasteele, C.: Fluidized bed waste incinerators: Design, operational and environmental issues. Prog. Energy Combust. Sci. 38(4), (2012)