farmatic Anlagenbau company presentation Powerful biogas plants focus in the wastewater, waste treatment and energy generation

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1 Thai-German Technology Conference Biogas November 20, 2017 farmatic Anlagenbau company presentation Powerful biogas plants focus in the wastewater, waste treatment and energy generation Dipl.-Ing. Helmut Muche farmatic Anlagenbau GmbH Kolberger Straße Nortorf Germany 1

2 farmatic Anlagenbau company profile Company history of 50 years Annual turn-over approx Mio 50 Employees Headquarters in Nortorf (70 km North of Hamburg, Germany) ISO certified quality management Over 100 biogas plant references Over 100 wastewater treatment plant references Over 3,000 bolted steel tanks constructed worldwide 2

3 Business Sectors Biogas Plants Tank and Storage Solutions Wastewater Treatment Thermal Energy Storage TES Digestion Plants for organic Waste Biogas Agriculture SBR-Plants Continuous Flow Plants Cold Water Storage Hot Water Storage Agricultural Biogas Plants Engineering Services Industry Energy Storage Equipment: Aerators, Mixers, Decanters Industrial & Municipal WWTP PTH: Power-To-Heat 3

4 We use bolted steel tanks for our biogas plants Storage solutions with capacity up to 20,000 m³ Digesters up to 8,000 m³ Our modular design allows flexible solutions Tanks can have any size and any width from 50 m³ - 20,000 m³ 4

5 We use CSTR digesters for our biogas plants CSTR = Constantly Stirred Tank Reactor Digester Material Roof Stainless Steel Gas Zone Stainless Steel or Glass Coated Steel Liquid Zone Glass Coated Steel Operational Temperatures Thermophilic C Mesophilic: C Watch the 3D animation on Youtube: 5

6 Characteristic CSTR = Constantly Stirred Tank Reactor Advantages Chemical reactor design Permanent stirring 24 hours a day, 7 days Very good mass and heat transfer Short reaction times = small tank No swimming layers No sink layers Very low operating and maintenance costs Very long life span of the system Low overall life cycle cost Low footprint of facility Very simple technology High material quality High volumetric load possible High dry matter content possible smaller digester volume needed Use of highly efficient vertical mixers Low energy consumption for mixing Danger to groundwater easily eliminated Easy explosion protection 6

7 Features of a plant for food and organic waste 7

8 Bagasse 285 kg/mg cane Filter cake 30 kg/mg cane Biogas 2.2 m³/mg cane Crystal sugar kg/mg cane Main product By-product Between product Sugar cane Cutting Leaching with hot water Sugar cane juice Purification Concentration Crystallisation Stillage Filter cake Ethanol 10.1 l/mg cane Biogas 4 m³/mg cane Capacity sugar mill : 6,000 to sugar cane per day Production sugar 622 to/day Production filter cake 180 to/day Production ethanol 61 klpd (m³/day) Production stillage 640 m³/day Molasses 45 kg/mg cane Alcoholic fermentation Distilling mashes Distillation Stillage 106 l/mg cane Methane fermentation Production biogas Filter cake 13,284 m³/day Stillage 24,256 m³/day Electricity 3,765 kw Clean waste water Waste water treatment Digestate 8

9 9.0 kg Diesel /ha*yr 8.2 kg Glyphosate /ha*yr 3.0 kg Paraquat/ha*yr Sun Plantation with Oil Palms 122 palms/ha Soil Rain Nutrients artificial nature Artificial nutrients kg /ha*yr N: 80 P: 14.5 K: 86.6 Ca: 15 Mg: 30.7 Sources Christopher Teh Boon Sung: Availability, use, and removal of oilpalm biomass in Indonesia Report prepared for the International Council on Clean Transportation Silalertruksa, Thapat; Gheewala, Shabbir H.: Environmental sustainability assessment of palm biodiesel production in Thailand Energy 43 (2012) PALM OIL PRODUCTION ENERGY AND NUTRIENT FLOW Nutrient recovery kg /ha*yr N: 19.6 P: 1.1 K: 42.7 Ca: 4.5 Mg: 2.7 Compost 0.95 to/ha*yr Water 15.7 m³/ha*yr Power plant Power production kwh el /ha*yr Shells : 2,012 Fibres : 4,135 Biogas : 3,225 Total, gross : 9,372 Total net : 8,769 Specific data's for a mill output per 1 to FFB per hour, 200 ha plantation area is required Biogas 1,466 m³/ha*yr kg Diesel /ha*yr Shells 1.8 to/ha*yr Power consumption 603 kwh el /ha*yr Fibres 3.9 to/ha*yr 60 to FFB/h 5.5 MW el POME 18 m³/ha*yr Biogas POME 585 m³/ha*yr FFB 30 to/ha*yr Nutrient loss kg /ha*yr N: 88.2 P: 13.2 K: Ca: 24.3 Mg: 23.1 Mill EFB 6.9 to/ha*yr Biogas plant Biogas EFB 795 m³/ha*yr Digestate 26.8 to/ha*yr Kernels 2.4 to/ha*yr 33.6 kg Diesel /ha*yr DC 0.96 to/ha*yr CPO 6 to/ha*yr Biogas DC 86 m³/ha*yr 9

10 Example: Biogas plant in a palm oil mill in Indonesia Requirement of the grid operator Task Solution Target Supply of a constant amount of electricity with high availability Operating time more than 8,000 hours per year POME is waste water, the biogas plant is a part of waste water treatment POME is not constantly available over the course of the week and the course of the year (low season / high season) POME is used as a base substrate. Volume compensation over the week is possible with a small buffer tank. Utilization of the Decanter cake (storable for short periods) Empty Fruit Bunches for peak coverage (storable) Optimization of the economic efficiency of the biogas plant with longer operating times 10

11 Key components of a biogas plant for POME 11

12 Comparison: CSTR digester lagoon digester Capital and operating costs Lagoon System Continuous Stirred Tank Reactor Fresh Fruit Bunch to/h Volume flow POME m³/d Volume digester 22,000 5,400 m³ Hydraulic Retention Time d Investment cost 26,000,000 29,200,000 THB Installed power agitators 685, , kw Energy consumption 130, ,000 kwh/y Maintenance cost 4,400, ,000 THB/y Unit 12

13 What benefits can we offer? Biogas plants with state-of-the-art technology Biogas plants with low self energy consumption Biogas plants for all potential substrates Utilization of waste and by-products from agriculture sector Treatment of waste water for purification and energy generation Utilization of energy crops such as Napier grass Utilization of Municipal Solid Waste Design of the biogas plant Construction and commissioning of the biogas plant in cooperation with our Thai partner Large local share of the construction Financing of the biogas plant as BOOT model with our Thai partner Maintenance and operation of the biogas plant 13

14 R E F E R E N C E S BIOGAS PLANT SKÖVDE Göteborg Energi AB, Skövde, Sweden Year of commissioning 2011 Gas yield 800 Nm³/h Digester 2 x 4,350 m³ Post-digester 1 x 2,400 m³ Substrates: Whey Expired food Slaughterhouse waste Wastewater Spoiled milk Special Features 71,000 t/a 10,000 t/a 8,000 t/a 7,000 t/a 3,000 t/a Gas upgrading Thermophilic process (55 C) as pasteurisation method Sophisticated heat management through heat storage and recovery Very few pumps required, 80 % of the plant operates through hydrostatic pressure farmatic Anlagenbau GmbH Kolberger Straße Nortorf Germany info@farmatic.com

15 R E F E R E N C E S BIOGAS PLANT LUSTENAU Häusle GmbH, Lustenau, Austria Year of commissioning 2013 Gas yield 600 Nm³/h Digester 1 x 3,900 m³ Post-digester 1 x 5,100 m³ Substrates: Organic fraction of MSW Cattle manure Grease trap contents (fat) 17,000 t/a 5,000 t/a 2,000 t/a Special Features Expansion of an existing dry fermentation plant with a wet digestion line Hygienisation at 70 C Sophisticated separation of solids, impurities and other unwanted materials by screw press and hydro cyclone farmatic Anlagenbau GmbH Kolberger Straße Nortorf Germany info@farmatic.com

16 R E F E R E N C E S BIOGAS PLANT ARAVETE Aravete Biogas, Aravete, Ambla, Estonia Year of commissioning 2012 Installed power 2,000 kw Digester 2 x 3,500 m³ Post-digester 1 x 2,500 m³ Substrates Cow manure Dry dung Poultry manure Gras silage Brewery waste Whey 63,000 t/a 25,000 t/a 5,200 t/a 1,000 t/a 8,000 t/a 4,000 t/a Special Features Complex mix of substrates High dry matter content in some substrates requires heavy duty cutting and feeding machinery farmatic Anlagenbau GmbH Kolberger Straße Nortorf Germany info@farmatic.com

17 Thank you! Helmut Muche Our partner in Thailand International Sales Multico Green Technology Co., Ltd 75 Soi Ramkhamhaeng 112, (Germany) Bangkok (Thailand)