Presentation of the results of the technical feasibility study for a biogas plant in Suluova

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1 Presentation of the results of the technical feasibility study for a biogas plant in Suluova Presenter: Dipl.-Ing Helmut Berg 14 October 2011, Amasya initiative on the basis of a decision adopted by the German Bundestag.

2 Concept to improve the water quality of Tersakan brook and for the construction of a biogas plant in Suluova, Amasya Dipl.-Ing. Helmut Berg Ingenieurbüro H. Berg & Partner GmbH Malmedyer Straße 30, Aachen, Germany Tel.: info@bueroberg.de initiative on the basis of a decision adopted by the German Bundestag.

3 Project financing Federal Ministry for Environment, Nature Conservation and Nuclear Safety (BMU), Berlin Project management German Agency for International Cooperation (GIZ), Eschborn Turkish Partner Institution Turkish Ministry of Environment and Forestry (MoEF) 3

4 Suluova Tersakan Yeşilirmak (Source: 4

5 (Source: 5

6 (Source : 6

7 Tersakan brook Suluova Industrial breeding zone (Source : 7

8 The agricultural location Suluova in the future Optimal conditions for mixed farming Fertile arable land, rich in humus (27,400 ha): sugar beet, wheat, corn, onions, fruit growing and horticulture efficient irrigation system (60 % of arable land) infrastructure, trade routes powerful cattle and poultry production Pronounced upstream and downstream fields of agriculture: strong Agribusiness/Agri-food industry Upstream : production of animal feed, fertilizers, seed Downstream: sugar refineries, slaughterhouses, store houses 8

9 Integrated cattle and poultry production Animal feed factory with regional supply (Kozlu) Fattening feed for cattle and poultry Further increase of livestock farming in Suluova (currently 40,000 cattle) due to increasing national demand and government aid Modern integrated poultry farming by Kozlu (egg production) Potential for 1 Mio. animals with 900,000 eggs per day chicken faeces as raw material for the production of biogas and organic fertilizer 9

10 Analysis of the pollution of Tersakan brook Insufficient waste water treatment of the municipal waste water and the sugar refinery Substantial environmental impact and greenhouse gas emissions by direct discharge of animal waste and waste water into Tersakan brook Bad smell in the city and at the lakes and rivers Emissions of climate-damaging nitrogen oxide and methane Excessive nitrogen and phosphorus concentration in surface waters and ground water Damage to aquatic organisms (in particular fish) Restriction of water use for land irrigation Loss of farm fertilizer because of discharge of animal waste into the rivers and lakes 10

11 Pollution of Tersakan brook by discharge of slurry 11

12 Concept for the reduction of environmental pollution caused by waste water and animal waste Separate collection and treatment of domestic waste water in a mechanicalbiological municipal sewage treatment installation, discharge of purified waste water into rivers and lakes Mucking out of bull stables by scraping systems instead of cleaning by using water Construction of decentralised underground slurry storage tanks (approx. 1 week storage) Withdrawal of slurry from the decentralized storage tanks by vacuum tankers; centralized collection of slurry and delivery to biogas plants for biomethanization Use of biogas in a combined heat and power unit; sale of electricity, organic fertilizer and heat Use of fermented substrata as fertilizers to replace mineral fertilizers 12

13 Dung-removing with convertible scraper (Source: 13

14 = 3,75 m Liquid manure collection tank built from concrete shaft rings storage capacity : 20,00 m³ Waste water collection systems One-tank version built from concrete shaft rings = 3,00 m (Source: capacity approx. m³ Inside diameter mm depth appr. mm 10, , ,

15 Vacuum withdrawal of slurry from the collection tank (Source: KTBL, Gülle Mengen genau ermitteln, Proben richtig ziehen) 15

16 Concept of a biogas plant in Suluova cattle shed self-priming vacuum tank trailer combined heat and power unit urinary and faeces chicken farm collection tank (1 week) biogas CHP main (local main) heat (use for example glasshouse) chicken faeces biogas plant self-priming vacuum tank trailer urinary and faeces liquid fertilizer storage tank with stirring device grit channel media pump 16

17 Process flow and material flow scheme of a biogas plant Source: 17

18 Biogas plant in Germany (Source: 18

19 Substrata for the biogas plant in Suluova (first stage) Cattle slurry from bull fattening (approx t/a from cattle) Chicken faeces (approx t/a from chicken) More substrata (second stage) Cattle slurry (approx t/a from cattle) Chicken faeces from the farm in Suluova and the planned farms in Amasya and Merzifon (approx t/a from 1.8 Mio. chicken) Sludge from the planned biological waste water treatment plant Slaughterhouse waste Onion waste Canteen waste Waste from the food industries 19

20 Using the heat from the CHP Heating of glasshouses Production processes in food industry (e.g.: production of canned food) Production of organic fertilizer pellets 20

21 Sale and use of digestates as fertilizer Storage of liquid fertilizer (rich in nitrogen, phosphorus and potash) in a sealed lagoon (storage capacity at least 8 months) Collection and distribution of the liquid fertilizer when required by sugar beet, corn-, crop- and onion farming Surrogate for mineral fertilizer by providing t/a of nitrogen, 785 t/a of phosphorus and of potash in the fermented substratum 21

22 Slurry lagoon (Source: 22

23 Climate-friendly output of the liquid digestates (Source: 23

24 Spreading out the digestates before sowing (Source: Ludwig Volk, FH Südwestfalen, SS 2010) 24

25 Visiting the existing farms at Suluova Fattening farm with a capacity of 40 bulls Fattening farm with a capacity of 400 bulls Farm that combines milk production, raising and fattening 25

26 Fattening farm with a capacity of 40 bulls 26

27 Fattening farm with a capacity of 400 bulls 27

28 Fattening farm with a capacity of 400 bulls 28

29 Farm that combines milk production, raising and fattening Self-developped and self-made scraper system for inside and outside keeping; storage of slurry in a slurry basin 29

30 Fully-slatted floor house for fattening bulls in Germany 30

31 Housing system with cubicles (straw bed) on a sloping floor for fattening bulls in Germany 31

32 Parts of the biogas plant in Suluova collection container with agitator (500 m³) grit seperator 2 pumps (feed) medium pump 5 fermenters (5 x m³, with two production lines) 4 CHP (4 x 500 kw el. ) sealed slurry lagoon for fermentation liquids (capacity: m³ for 8 months) Dipl.-Ing. Helmut Berg 32

33 Dimensions of the biogas plant Suluova Faeces from 1 Mio. chicken Slurry from fattening bulls Annual production of biogas Engine power of CHP t/a t/a 7,69 Mio. m³/a kw el. Electrical degree of efficiency 41 % Thermal degree of efficiency 42 % Production and sale of electricty Production of heat 15,6 Mio. kwh/a 16,1 Mio. kwh/a Dipl.-Ing. Helmut Berg 33

34 Economic feasability study Investment costs (total) Biogas plant Operation costs (total) Biogas plant /a Income (total) Biogas plant - Sale of electricity /a - Sale of fermented rests /a Profit (before taxes) Biogas plant /a ROI / = 5 years 34

35 Results Establishing a climate friendly disposal of agricultural wastes Reducing the impact on environment by avoiding harmful immissions from livestock farming Production of electricity and heat from agricultural wastes; replacement of fossil resources (reduction of CO 2 ) Production of fertilizer containing phosphorus, nitrogen and potash with a large content of humus instead of pollution of waters Improvement of water quality in order to obtain a good ecological state and to fulfil the European guidelines Innovative construction of sheds in order to install a cleaning system without using water discharging into the sewerage system Realization of German animal rights standards 35

36 What is gained? Sustainable economical development and a livable environment! (Source: 36

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