The Art of integrating solid and liquid waste streams

Transcription

1 The Art of integrating solid and liquid waste streams Dr. Marc R. Stammbach / MD HZI Australia BANZ Workshop, 19 Sep 2017 Why bother? 2 1

2 Organic Product Cycle: Elementary Human Inputs and Outputs Oxygen food energy air waste Carbon Dioxide 3 Organic Product Cycle Solved Once Upon a Time in Equilibrium With Nature Oxygen food energy air waste Carbon Dioxide recycle 4 2

3 Segregation of Food Production and Consumption Does Not Include the Recycling of the Organic Waste As Fertiliser Consequences of Increase in Population food recycle 5 Australia s & New Zealands waste composition in comparison Lower revenue countries Average revenue countries High revenue countries Australia & New Zealand Organic / fermentable Paper and cardboard Plastics Metals Municipal waste composition (%) Humidity 50% 80% 40% 60% 20% 30% 20% 30% Calorific power in kcal/kg 800 1,100 1,100 1,300 1,500 2,700 1,500 3,000 Glass Notes: Adapted from CycleOpe; Examples of lower revenue countries include India and Africa; Examples of average revenue countries include Argentina and EU New Member States; Examples of higher revenue countries include the US and EU

4 Resource recovery along the development path Country revenue GDP in $/capita pa Municipal waste by kg/capita pa Lower revenue countries Average revenue countries High revenue countries < $5,000 $5,000 $15,000 > $20,000 > $20, < 70% 70% 95% > 95% Formal collection rate Waste treatment Australia & New Zealand > 95% Landfill sites > 90% Selective collection Wildcat landfills > Start of selective Waste to Energy 50% collection (Europe) Informal recycling Organised recycling Recycling > 20% 15% (5%) plus informal recycling More supportive regulatory framework & reliable data available Selective collection No Waste to Energy Recycling > 20% No comprehensive national strategy; Limited data Notes: Adapted from CycleOpe; Examples of lower revenue countries include India and Africa; Examples of average revenue countries include Argentina and EU New Member States; Examples of higher revenue countries include the US and EU-15 7 EfW closes the energy cycle Material and energy recycling are complementary Material Recycling AUS & NZ 43% EU 40% CH 50% Reduction CO2 Reduction EfW saves up to 2t CO2 per treated t of waste. Methane emissions AUS & NZ 57% EU 36% Groundwater CH 1% leakage Thermal Recycling EfW offsets CO2 from power production. AUS & NZ 0% EU 24% CH 49% EfW eliminates Methane emissions from Landfill. 8 4

5 Circular Economy We need at least three bins to achieve zero waste to landfill Energy & Compost Energy & Material from biowaste with anaerobic digestion from non recyclable waste with thermal treatment Recycling Recycling Direct Recycling Compost & fertiliser Glass, paper, metals Metals & minerals 9 East Rockingham WtE Project in Perth, Western Australia, Scheduled to start full operation 1 July 2021 Client SPV HZI/NEC/TRIBE Key Dates FC/NTP Start-up 1 July 2018 approx 3 years after FC/NTP Technology Furnace Energy recovery Flue gas treatment Grate furnace (air-cooled) 5-pass boiler, turbine generator set SNCR, dry system Technical Data Fuel Waste capacity Net calorific value Thermal capacity Residual MSW and C&I 300,000t/a MJ/kg 1 x MW l Thermal treatment of 300,000 tpy residual waste from councils and industry after source separation of recyclables and organics l 96% landfill diversion 4% flue gas treatment residues to landfill l Zero greenhouse gases from landfill l Energy-efficient design with an R1 factor of 0.77 l 28 MW base electricity production 10 5

6 Anaerobic Digestion of organic waste 11 Why organics recycling with Anaerobic Digestion (AD)? Closing the nutrient cycle while generating energy Typical biogas yields: - Green waste: ~ 80 Nm3/t - Kitchen waste: ~ 180 Nm3/t - OF MSW: ~ 150 Nm3/t 12 6

7 Kompogas dry AD Designed for a large variety of input materials Household bio-waste Catering and kitchen waste Organic fraction of MSW / residual waste Green waste Market and vegetable waste Expired food from supermarkets Organic waste stream changes over time => requiring a future-proof system! 13 Kompogas dry AD The continuous plug-flow digester of the market and technology leader Input Biogas DM: 20-50% DM: ~30% Discharge DM: 25-30% Horizontal plug flow Thermophile temperature Single shaft agitator Internal inoculation 14 7

8 Basis of our Success in Anaerobic Digestion: First-Class Technology and Turn-Key Capabilities Project Management Proprietary Technology from HZI Feeding System Digester Discharge System Engineered by HZI Electrical and Control Technology Balance of Plant Energy Use Managed by HZI Site and Building Services Engineering Integrated Solution Dewatering Maximized Efficiency Reliable Execution 15 Waste mixture In order to get the optimal input and output properties for the process different waste must be mixed 1/3 Yard waste 2/3 Catering/ kitchen waste 16 8

9 Waste composition What are the optimal input properties? Dry Substance (DS) % Organic dry Substance (ods) % (of DS) ods anaerobic degradable % (of ods) Dimensions < 60 mm ph Total Nitrogen (Kjedahl) < 8 g/kg C/N ratio > 18 The nitrogen content and C/N ratio is a limit for the proper biological process, of all anaerobic systems! 17 Organics reception 18 9

10 Reception, Pre-treatment Reception in a pit bunker Feeding the pretreatment with an automatic crane Feeding the fermenter directly from the pretreatment Operation mode in intervals during 24h / 7d / week Pit bunker Utzenstorf / CH 19 Pre-treatment Star sieve Shredder Magnetic separator 20 10

11 Intermediate storage Storage bunker Rostock / Germany 21 Fermentation Thermophilic conditions maximum activity Input Biogas Discharge Thermophilic temperature Advantages over mesophile system: Hygienic High gas yield 22 11

12 temperatur The Kompogas system Thermophilic conditions maximum activity 55 C thermophilic 37 C mesophilic activity 23 Fermentation Dry system, Plug flow Defined retention time 55 C Plug All conditions under control (acid profile) Defined order of biological process stages No / low activity in output No short circuits Advantages over mixed systems: Hygienic Process control High gas yield Controlled, hygienic. Minimal water addition

13 Fermentation Why Inoculation? Internal inoculation Inoculate input material with bacteria Fast process start High biological load KOMPOGAS patent (exclusive user) Low inoculation rate Discharge Simple system High degradation rate, low space requirement. 25 Fermentation Fermenter inside view 26 13

14 Dewatering How to use the processed substrate After fermentation, the output / dewatering press separates the substrate in: Digestate will be composted in the composting area Presswater The press water can be used for moistening the input material and the water surplus can be used in agriculture as liquid fertiliser Usage by farming or agriculture, certificate for fertilisation 27 Digestate to compost The anaerobic conditions of the solid phase must change into aerobic conditions. After 3 weeks aerobic composting, high quality compost is created Usage in gardening or agriculture 28 14

15 Pasteurized products How are the products used? Liquid fertiliser Compost 29 What is biogas (CH4 and CO2) good for? 30 15

16 Biogas to Biomethane Biomethane = attractive alternative to fossil fuel 1 Nm3/a biomethane = ca. 1 litre diesel fuel CNG and LNG taxation in New Zealand: - CNG is taxed at NZD/lt - No Road User Charge applies Upgrading technologies available (HZI in-house) Amine washing => high purity: up to 99.5% => methane slip: <0.1% => pressure: near atmospheric Membrane => pressure: up to 16 bar => small foot-print => no heat required HZI membrane technology HZI amine scrubbing technology 31 Produce your own CNG or renewable diesel Biomethane = attractive alternative to fossil fuel 1 Nm3 biomethane = ca. 1 litre diesel fuel 20,000 tpy organics Typical biogas yields (55% methane): - Green waste: ~ 80 Nm3/t 0.9 Mio litres diesel/y - Kitchen waste: ~ 180 Nm3/t 2.0 Mio litres diesel/y - OF MSW: ~ 150 Nm3/t 1.7 Mio litres diesel/y 32 16

17 Power to Gas - Bio-Methanation Utilising CO2 Power to Gas (PtG): ETOGAS H H H H = + Synthetic Bio-methane CO2 33 Werlte, Germany Client Start-up Technology Plant type Gas type Technology type CO2 usage Technical Data Plant Capacity CO2 production Biomethane (CH4) production Syngas production Audi AG 2013 A-Series incl. AD plant Biogas Amine scrubbing Syngas production by methanation of CO2 and H Nm³/h flue gas kg/h 550 Nm³/h l Complete EPC turnkey project incl. CO2 capture plant based on amine scrubbing for syngas production, incl. civil works l CO2 is supplied to a downstream methanation process to produce syngas l Process heat for CO2 scrubbing is supplied by woodchips boiler HZI Biomethan CO2 References 34 17

18 Surplus / negative value electricity is turned into methane ETOGAS supplied world s so far largest industrial power to methane project ETOGAS stabilises grid and produces methane in synergy with solar and wind farms 35 Draškovec, Croatia Client Start-up AAT-Geotermae d.o.o Technology Plant type Gas type Technology type CO2 usage C-Series Flue gas Amine scrubbing Recirculation into aquifer Technical Data Plant Capacity CO2 production Nm³/h 1,5 t/h l Carbon capture installation using HZI amine scrubbing technology l High level of impurities in flue gas stream originating from CHP installation l High CO2 quality requirements due to recirculation into methane containing aquifer l Plant currently under construction HZI Biomethan CO2 References 36 18

19 Some of more than 80 references 37 Anaerobic Digestion with Kompogas Faedo, Italy (1 out of > 80 Kompogas References) Plant Capacity Compost Biogas Production Bio CNG Equivalent Net Energy Efficiency 32,000 t/a Green & Foodwaste 29,000 t/a 3,800,000 Nm3/a 2,100,000 Nm3/a 66 Nm3 Bio CNG/t, 660 kwh/t Energy & Biogas from Waste for a Carbon Free Economy, Andres Kronenberg

20 Terni, Italy Client Start-up Terni Energia / Cesaro Mac Technology Plant type Input material Digester type Biogas usage Biowaste plant FORSU* & green waste PF concrete/steel digester CHP Technical Data Plant Capacity Bypass Material Biogas production Electricity production CHP installed: Solid digestate Liquid digestate 17`500 Mg/a Mg/a 2`400`000 Nm 3/a 4`920`000 kwh/a 1 x 700kW el 16`500 Mg/a - l Partial stream Kompogas process bypassing 40% of material for mixing with digestate - no liquid digestate is generated l Very high gas yield of 170 Nm3/t mainly coming from FORSU l Turnkey project including composting plant supplied by Cesaro Mac Import with sub-supply of Kompogas core module digester l Full use of solid digestate to produce high quality compost and thereby closing nutrient cycle 100% l Main drivers for project is gate fee for FORSU and production of electricity * Frazione Organica del Rifiuto Solido Urbano 39 Rijesenhout, Netherlands Client Start-up Meerlanden Holding ev 2010 Technology Plant type Input material Digester type Biogas usage Biowaste plant GFT (green & kitchen waste), grease PF concrete/steel digester Biomethane & grid injection Technical Data Plant Capacity Biogas production Biomethane production Energy content Solid digestate Liquid digestate 48`000 Mg/a 2`600`000 Nm 3/a 12`200`000 Nm 3/a 12`200`000 kwh 40`000 Mg/a 5`000 Mg/a l Partial stream Kompogas process (patented), hence no liquid digestate l Biogas upgrading to 99,5%CH4 content and grid injection l CO2 capturing while biogas upgrading and reuse in neighbouring greenhouses l Use of condensate water from composting tunnels for street cleaning and surplus heat for neighbouring greenhouses l On site CNG fuelling station for Meerlanden s own garbage trucks 40 20

21 Winterthur, Switzerland Client Start-up Kompogas Winterthur AG 2014 Technology Plant type Input material Digester type Biogas usage Biowaste plant Comingled green and food waste PF1500 steel digester Biomethane & grid injection Technical Data Plant Capacity Biogas production Biomethane production Solid digestate Liquid digestate 23`000 Mg/a 1`800`000 Nm 3/a 1 000`000 Nm 3/a 11`800 Mg/a 11`400 Mg/a l Another Kompogas dry AD plant with high level of automation l EPC turnkey contract for complete plant, incl. civil works l Standardized steel digester with nominal volume of 1500m3 l Biogas is upgraded and injected into the gas grid (upgrading by Amine washing technology) 41 Integration of Kompogas plug-flow digesters into Biowaste (Source Segregated Organics, SSO) or MBT plants (Organic Fraction of MSW, OFMSW) Backnang-Neuschönta / Germany (SSO) Fulda / Germany (SSO) Doha / Quatar (OFMSW & SSO) 42 21

22 Doha, Qatar Client Start-up Technology Plant type Input material Ministry of Municipality & Urban Planning 2011 Digester type Biogas usage Integrated MSW Management Centre MSW / Organic Fraction of MSW, green waste 5xPF concrete digester CHP Technical Data Plant Capacity Biogas production Electricity production Mg/a (AD: Mg/a) `000 Nm 3/a 56`900`000 kwh/a l Large integral waste processing plant combining mechanical sorting, Kompogas dry AD and thermal energy from waste of residual solid waste l Largest Kompogas dry AD plant in the world with 15 x PF1300 concrete digesters operating in parallel (12 x OFMSW + 3 x green waste) l Main driver for dry AD: production of compost l Biogas usage in Combined Heat and Power (CHP) plant 43 Montpellier, France Client Start-up Montpellier Agglomération 2008 Technology Plant type Input material Digester type Biogas usage MBT plant MSW / Organic Fraction of MSW 4 x PF concrete digester CHP Technical Data Plant Capacity Biogas production Electricity production Solid digestate Liquid digestate Mg/a (AD: Mg/a) `000 Nm 3/a 30`000`000 kwh/a 28`000 Mg/a none l Largest AD plant in Europe, being integral part of an MBT l High impurity content in organic fraction sorted from MSW l High energy yield: in average 140 Nm3 of biogas per metric ton input material l Dewatering system with centrifuge and subsequent water treatment plant l Full-fledged composting plant, using tunnels and covered windrows l Odour treatment with water/acid scrubbing system, fully enclosed biofilter and activated carbon 44 22

23 Bologna is largest AD project currently under execution in Europe What? REAL circular economy Source separated biowaste will be anaerobically digested with Kompogas Where? Italy Bologna Who? HERAmbiente Integration in existing composting plant How? tpy biowaste 4x Kompogas PF1800 digesters tpy quality compost > Nm3 biogas / year By whom? Cesaro Mac & HZI in cooperation 45 Summary Application: Dry Anaerobic Digestion is the system of choice for solid organic fractions Industrially proven in Europe Capable to produce compost and renewable energy (electricity, BioMethane, BioCNG and BioLNG) Strategic fit: Closes nutrient, carbon and fuel cycle Removes organics based greenhouse gases from landfill A must do to achieve the COP21 / Paris Agreement Affordability: Source separated collection of food & green waste Scale matters $60-$120/t urban organics based on reliable & high biogas production 46 23

24 Waste is our Energy. Engineering is our Business. Sustainable Solutions are our Mission. Check our References