From Pilot to Full Scale Operation of a Waste-to-Protein Treatment Facility. Christian Zurbrügg, Bram Dortmans, Audinisa Fadhila, Stefan Diener

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1 From Pilot to Full Scale Operation of a Waste-to-Protein Treatment Facility Christian Zurbrügg, Bram Dortmans, Audinisa Fadhila, Stefan Diener

2 Just one slide on the rationale Waste management is still a challenge in low income settings Organic solid waste is 50-80% of waste mass and is yet hardly recovered and recycled Strategies and policies are more and more including aspects of circular economy Current organic waste recovery/recycling still faces a «value chain» challenge Compost typically has limited value and customers are not where the product is Biogas often suffers from cheap energy competition Char production (or biomass fuel) is promising but limited to dry materials How else can we create value from waste?

3 Possibilities Lohri C.R., et al. (2017). Treatment technologies for urban solid biowaste to create value products a review with focus on low and middle income settings. Reviews in Environmental Science and Bio/Technology. 16/1, pp D I R E C T U S E B I O L O G I C A L T R E A T M E N T P H Y S I C O - C H E M I C A L T R E A T M E N T T H E R M O C H E M I C A L T R E A T M E N T T E C H N O L O G I E S P R O C E S S E S Direct land application Direct animal feed Black Soldier Fly treatment Composting Vermicomposting Anaerobic digestion Direct combustion Transesterification Densification Liquefaction Fermentation Pyrolysis Gasification P R O D U C T S Worms Residue Digestate Glycerol Pellets/ briquettes Compost Larvae Biogas Bio ethanol Biodiesel Char Biooil Gas Meat/fish production Crops production Transport fuel Cooking fuel/ heat/electricity Animal husbandry E N D U S E Agriculture Bio-energy

4 Black Soldier Fly, Hermetia illucens Mating Eggs Young larvae Larvae feed on organic material Fruits & vegetables Food waste Slaughterhouse waste Chicken manure Human faeces Creates value from waste Adult fly Pupae ~1 month Prepupae Larvae Conversion of 1 ton of food waste into 250 kg fresh larvae within 12 days Larvae contain ~40% protein and ~30% fat Good substitute Fishmeal Soymeal Material reduction of 70-85% dry matter

5 Engineering BSF Engineered life cycle Waste treatment Control over: # prepupae # eggs # flies 5 DOL production Survival rate Retention rate Development time Waste treatment requires a steady mass production of small larvae Engineering of the life-cycle

6 Pilot facility: Surabaya, Indonesia

7 Engineering BSF

8 Post-processing BSF

9 Costing BSF

10 Costing BSF (1 t/day) Activity Unit Euro/Year % of total Rearing units 31% Labour 2483 Consumables 1095 Annual equipment costs 1526 Other units 56% Labour 4966 Consumables 881 Annual equipment costs 3545 Indirect costs % Total % Scaling to x5 without much addition Scaling will require some automation $ Labour 45% Consumables 12% Equipment 30% t/d

11 Challenges Waste Sourcing BSF Treatment Technology Waste-derived products & markets Nursery Treatment Cherry-picking or solving public challenges? Quality control! Multiple revenue streams!

12 BSF research conducted Process engineering Life cycle Feeding substrates Reproduction cycle Operation Waste treatment technology Rearing facility Product safety Health risks (pathogens, heavy metals, pharmaceuticals) Post-treatment options Technology implementation Pilot facilities Sweden: optimization of rearing facility Indonesia: treatment of MOSW Tanzania: fish feed production from fruit waste Sustainability aspects Economy Time-motion-studies Economy of scale Development of business models Environment LCA Greenhouse gas emissions Circular economy (integrated systems) Education/Dissemination Beginners Guide MOOC-Module

13 BSF - LCA Life cycle analysis study in Indonesia Methods Measurement of CH 4 and N 2 O during BSF treatment Comparison with other organic waste treatment technologies (composting) Results Direct GHG emissions significantly lower for BSF than composting Electricity consumption and source of electricity most relevant for LCA GWP [kg CO2/ton waste] BSF larvae composting Treatment option Standard composting Fishmeal transp. Fishmeal prod. BSF: Other Composting: Energy BSF: LPG BSF: Electricity Composting: Direct emission BSF: Direct emission OVERALL GWP

14 Conclusions views

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