DIGESTING FIBRUOUS MATERIALS AND WASTE IN MULTI STAGE BIOGAS PLANTS

Transcription

1 DIGESTING FIBRUOUS MATERIALS AND WASTE IN MULTI STAGE BIOGAS PLANTS Snow Leopard Projects GmbH Marktplatz Reisbach Germany Eberl Agrar Energie Experts in Biogas High Performance Biogas Plants Especially for fibrous feedstock Thailand G.Urban 1

2 SNOW-LEOPARD-PROJECTS GMBH IS A BIOGAS PLANT DEVELOPER IN GERMANY, WHOSE OWNER HAS PIONEERED BIOGAS-PLANT-TECHNOLOGY SINCE 1995 Decentralised biowaste digestion from 1995 until 2009 for people in the districts Dingolfing-Landau und Rottal-Inn, Bavaria Dingolfing Landau Biogas plants in ownership and operation development of 2-stage digestion system Pfarrkirchen Since 2005 engineering and construction of biogas plants for customers G.Urban 2

3 SNOW LEOPARD PROJECTS GMBH (SLP) Founded (2011) from Rottaler Modell (since 1994) Managing Directors Katharina Danner and Walter Danner Biogas Entrepreneur since 1994 Spokesman of the Lower Bavarian Regional Group of the German Biogas Association (WD) Speaker of the AK Biogas at the German Solar Energy Society (WD) Development, planning and construction of 50 biogas plants in 12 countries in Germany, Europe, Africa, Asia and South America Consultant for the UN for biogas and Biomass to Energy (WD) Biogas Management School G.Urban 3

4 AWARDS (EXAMPLES) EXPO 2000 Project Innovation Prize Inn-Salzach-Euregio 2000 Bavarian Environment Prize 2000 Bavarian Export Prize G.Urban 4

5 BIOGAS PLANTS Snow Leopard Projects (SLP) directors have developed a unique 2-stage ad plant which is consistently up to 30 % more efficient than conventional 1-stage digestion plants (ad plants). This plants can operate with over 75 different types of feedstock. The design of a SLP 2-stage ad plant with 2 hydrolysis tanks, enables the plant to process up to 80 %. straw based manure feedstock. This is an exceptionally high percentage of the overall feedstock when compared to typical 1-stage ad plants, that mostly require a very homogeneous feedstock of energy maize or grass silage. therefore these biogas plants can digest waste with is allready locally available. G.Urban 5

6 INDUSTRIAL 2-STAGE AD BIOGAS PLANT (0,5 2 MWe), Germany Control Office CHP Engine Hydrolosys Tank 1 Pump Tank 2 Room These spezial 2-Stage AD plants are designed to provide a very stable and robust operating process for biogas production resulting in feedstock retention time of just 3 weeks, fewer interruptions and delays. In an average year the SLP 2-Stage AD plants currently in operation are performing between % full load hours. Storage Tank (Size according to EU Environmental Law) Digester Tank MINI BIOGAS PLANT (10 25 KWe) G.Urban 6

7 SLP HIGH PERFORMANCE BIOGAS PLANT 2-STAGE AD SYSTEM WITH SEPARATE HYDROLYSIS AND ACIDIFICATION Separate hydrolysis system with Batch Feeding > 30% higher biogas yield in comparison to the German KTBL standard 2004 Digestion of fibrous material (grass, straw, manure, etc.) maize stalks, vinasse, rice straw, sugar cane tops is a potential feedstock Digestion of energy rich material (slaughterhouse waste, fruit processing waste, olive pomace, and much others) Easier and simpler operation due to 2-stage biological process > 97% full load performance Industrial equipment 80 % Own key equipment controlling system, high density agitator, pump station G.Urban 7

8 BIOLOGICAL PROCESSES IN A 2-STAGE AD BIOGAS PLANT The biochemical processes are deliberately separated in a Snow Leopard 2-stage ad plant in order to optimise the biogas extracted (other than in a typical 1-stage plant where all processes have to be done in one tank and are not so high efficient). Feedstock Hydrolysis and acidification occur in the hydrolysis tanks and acetification and methanisation occur in the digester tank. By perfecting the biochemical processes of producing biogas into 2 separate stages, this 2-Stage AD plant will extract 99.5 % of the biogas potential in a given tonne of feedstock Hydrolosys Acidification Acetification Menthanisation Biogas EXAMPLES Chicken Litter Duck Manure Gras/Maize Silage Straw Food Waste Slaughterhouse Waste Pome and EFBs and much more... Lipids, Proteins, Carbohydrates COMPOSITION Fatty Acids, Amino Acids, Alcohols PROCESS Thermophilic 50 C 55 C PH VALUE Acidic 4,5 7pH COMPOSITION Volutile Fatty Acids, Alcohols PROCESS Thermophilic 50 C 55 C PH VALUE Acidic 4,5 7pH COMPOSITION Acedic Acids, Carbon Dioxide, Hydrogen PROCESS Mesophilic 41 C 44 C PH VALUE Neutral 7 8pH COMPOSITION Methane (55%), Carbon Dioxide (45%) PROCESS Mesophilic 41 C 44 C PH VALUE Neutral 7 8pH G.Urban 8

9 BIOMASS RECOVERY FROM WASTE WHAT TO DO AFTER COLLECTING? Dumping Nothing (but Polution) Composting Fertilizer Cattle Manure & Slurry Duck Manure Straw Pig Manure & Slurry Chicken Litter Landscaping Material Pome and even Emty Fruit Bunches Rice Husk And Straw Food Waste Slaughterhouse Waste... And Much More Digesting in SLP Biogas Plants Fertilizer Gas Elecricity Heat Brickets G.Urban 9

10 FEEDSTOCK EXAMPLE LIST We have experience with the following feedstock in own biogas plants: Energy Crops Agricultural Waste Industrial Biowaste Other Biowaste Maize, -silage Liquid cattle manure Overload food - beer Waste derived from Sudan grass Liquid pig manure - bread kitchens and restaurants Corn cob mix Duck manure - candy bars Grass Layer manure - vegetable MSW organic fraction Clover grass Broiler chicken manure - fruit Rye Grain products Meat bonemeal Sugar beet Horse manure Blood (slaughterhouse waste) Wheat Straw Cadaver meal Potato Olive waste (pomace) Fruit waste (rasberry) Vinasse China cabbage Sugar cane tops Whey Maize stalks Ice cream Milk waste G.Urban 10

11 DIFFERENT FEEDSTOCKS AND THEIR SUITABILITY FOR SINGLE STAGE OR TWO STAGE AD TECHNOLOGY 2-stage Biology Covers a wider range of Biomass as Feedstock Especially Highly Fibrous Biomass and very Energy Rich Biomass G.Urban 11

12 BIOGAS PROJECTS (SELECTION) IN TOTAL >40 PROJECTS FROM 10 KWEL TO 4 MWEL SCOPE OF SUPPLY IN RANGE FROM ENGINEERING TO TURN KEY High Performance Biogas Plant Simbach b.landau 500 kwel Start up: 2006 High Performance Biogas Plant City of Baden Baden 500 kwel Start up: 2009 High Performance Biogas Plant Ortner 250 kwel Start up: % High Performance Biogas Plant Energiehof Bieswang GmbH & Co.KG 600 kwel Start up: 2011 High Performance Biogas Plant Chile 4x1MWel Start up: 1MW June 2011 HPTC Biogas Plant Dadaab, Kenia 10 kwel Start up: February G.Urban 12

13 BIOGAS PROJECTS (SELECTION) IN TOTAL >40 PROJECTS FROM 10 KWEL TO 4 MWEL SCOPE OF SUPPLY IN RANGE FROM ENGINEERING TO TURN KEY George Fram Biogas Plant. Kenya 80 % G.Urban 13

14 EXAMPLE: HORSE MANURE (STRAW) DIGESTION AND UTILIZATION Horse manure and straw is difficult to digest due to the high fibre content. With the SLP 2-stage digestion the final digestate is after separation and drying a good biofuel in biomass boilers. Natural gas, heavy furnace oil and wood chips can be replaced. Very low clinker fall out due to low mineral content in the biofuel after leaching out of minerals in the hydrolysis tank. Regular boiler technology is suitable for the biofuel from the SLP AD plant G.Urban 14

15 DIGESTION OF HIGHLY FIBROUS MATERIAL HORSE MANURE WITH HIGH STRAW CONTENT 80% horse manure in the feeding ratio Maize straw and rice straw is a potential feedstock G.Urban 15 Snow Leopard Projects GmbH

16 BIOENERGIE LICHTENECK GMBH & CO. KG HORSE MANURE DIGESTION There is no silo maize! G.Urban 16

17 EXAMPLE: HPTC BIOGAS PLANT CONTAINERIZED FOR OFF GRID APPLICATIONS (HPTC = HIGH PERFORMANCE TEMPERATURE CONTROLLED) Biogas plants for rural areas in developing and emerging countries for the digestion of waste from markets and production Slaughterhouse waste for the production of cooking gas, electricity and productive heat With temperature control like big biogas plants for high biogas production G.Urban 17

18 MINI BIOGAS PLANT (10 25 KWe) Cattle Manure Gras (Fresh Or Dry) Market Waste Vegetable Waste Fish Processing Waste Oil Seed Waste Organic Municipal Waste... Same Biological Processes - Highly Efficient - Flexible Local Feedstock - Easy To Set Up - Replacement Of Diesel For Generators - Contribution To Own Energy Consumption - Reducing Local Costs -... GAS ELECTRICITY FERTILISER (CARBON CREDITS) Example: Food Waste (Kitchen) 300 Kg/Day= 10 Kw Food Waste (Kitchen) 1000 Kg/Day= 25kw G.Urban 18

19 REAL LIVE EXAMPLE: FERTILIZER QUALITY Banana plants at the WEMA centre, Mombasa (May 2008) All the bananas were planted on the same day: the small ones had no MBPP fertilizer (discharge effluent = organic fertilizer) the big was irrigated with MBPP fertilizer (see the person as reference) Without fertilizer With fertilizer G.Urban 19

20 WHY CHOOSE A 2-STAGE AD PLANT? The SLP 2-Stage AD Plant produces up to 30% more biogas than 1-stage AD plants. Feedstock can be up to 80% straw based manure (cattle manure, pig manure, horse manure or other fibrous materials). Cheaper agricultural feedstock or allready existing waste materials can be used (manure, slurry, chicken litter, spent mushroom compost, waste vegetables, fallow year rotation crop, maize straw, rape seed straw, grass from river flooding areas, slaughterhouse waste, Pome an EFB, etc.), rather than having to provide high quantities of energy maize (as often required by 1-Stage plants) Reduction of dumping costs and pollution. Easy access for maintenance. Feedstock can be changed daily if needed. Total retention time is only 3 weeks. The plant is small in size and needs less space. Consistently up to 30% more efficient (than conventional 1-Stage AD plants). G.Urban 20

21 WHY CHOOSE A 2-STAGE AD PLANT? Extending the vaue chain with the differnet outputs you get: Gas (for further use) Electrical Power Heat (and Cooling) Liquid Fertilizer Solid Fertilizer, Bio Fuel (eg. Pelletts) Jobs Serving the environmental regulations and needs G.Urban 21

22 CONCLUSION OUR TYPES OF 2-STAGE AD-BIOGAS PLANTS ARE MORE EFFICIENT, SMALLER AND HIGHLY FLEXIBLE UNIQUE IN DIGESTING WASTE AND FIBROUS MATERIALS! G.Urban 22

23 CONTACT Snow Leopard Projects GmbH Gregor Urban Marktplatz Reisbach Phone: +49-(0) Fax: +49-(0) Mail: G.Urban 23

24 SLP 2-STAGE AD PLANT VS. TYPICAL 1-STAGE AD PLANT LAYOUT Typical 1-Stage AD plant SLP 2-Stage AD plant Feeder Feeder Digester Tank Hydrolosys Tank1 Hydrolosys Tank2 Digester Tank Storage Tank Storage Tank G.Urban 24

25 SLP 2-STAGE AD PLANT VS. TYPICAL 1-STAGE AD PLANT FEEDING Typical 1-Stage AD plant SLP 2-Stage AD plant Continuous Feeding Digester is fed during the whole day every 30 minutes or every hour Batch Feeding Hydrolysis Tank is fed once a day or once every 2 days CHANGING FEEDSTOCK Typical 1-Stage AD plant SLP 2-Stage AD plant 4 6 Weeks Feedstock can only be changed over 4-6 weeks with up to 10% of the feedstock changed over the course of a day. Daily Feedstock can be changed daily if required. G.Urban 25

26 SLP 2-STAGE AD PLANT VS. TYPICAL 1-STAGE AD PLANT BIOLOGICAL PROCESS Typical 1-Stage AD plant SLP 2-Stage AD plant Digester Tank Hydrolysis Acidification Acedification Methanisation Hydrolysis Tank 1 Hydrolysis Acidification Digester Tank Acetification Methanisation Hydrolysis Tank 2 Hydrolysis Acidification All 4 biochemical processes happen in the digester tank. Usually mesophilic (30-38 C). The biochemical processes are separated into 2 steps. Hydrolysis tanks (50-55 C) and digester tank (41-44 C). TEMPERATURE Digester Tank C Mesophilic Hydrolysis Tank C Thermophilic Hydrolysis Tank C Thermophilic Digester Tank C Mesophilic Mesophilic ambient temperatures in a typical 1-Stage AD plant range from C. A SLP 2-Stage AD plant separates the temperature for hydrolysis in the hydrolysis tanks and methane production in the digester tank. G.Urban 26

27 SLP 2-STAGE AD PLANT VS. TYPICAL 1-STAGE AD PLANT PH VALUE Typical 1-Stage AD plant SLP 2-Stage AD plant Digester Tank 7 8 ph (Neutral) Hydrolysis Tank 1 4,5 7 ph (Acidic) Hydrolysis Tank 2 4,5 7 ph (Acidic) Digester Tank 7 8 ph (Neutral) Both digester tank and storage tank have a neutral ph value of between 7-8pH. RETENTION TIME The hydrolysis tank has an acidic ph value of 4.5-7pH. The digester tank is neutral at 7-8pH and storage tank is neutral at 7-8pH. Digester Tank Days Hydrolysis Tank Days Hydrolysis Tank Days Digester Tank Days Retention time in a typical 1-Stage AD plant is considerably longer than an SLP 2-Stage AD plant at between 60 and 120 days Retention periods for 2-Stage plants being 2-4 days for the hydrolysis tanks and days for the digester tank. G.Urban 27