ENERGY & ENVIRONMENT 17 th June 2011

Integration of anaerobic digestion and composting as a sustainable way to Recover organic wastes. Modelling of Biomass Power Plant

Dr. Eng. Massimo CALZATI

SOLUTION PARTNERSHIP FOR PROJECT DESIGN AND DEVELOPMENT OF BIOMASS & SOLAR

WHO WE ARE Studio Ecoingegneri Italian independent consultancy specialised in BIOMASS ,BIOGAS & PHOTOVOLTAIC projects Secret Power Turkish Solution Provider Company for Renewable Energy Power Plants specialised in WIND and SOLAR

 Walk Through Analysis

WHAT WE DO..

Feasibility Studies
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Life on Earth depends on two natural processes:

The Carbon cycle

The Nitrogen cycle

Both somehow affected by human activities

The modified Carbon cycle

Main responsibility lays with use of fossil fuels to fulfill growing energy needs worldwide Consequences are the Greenhouse effect at global scale and the various forms of local air pollution

The modified Nitrogen cycle

Contributes to both water (eutrophication) and air pollutions (GH effect)

Comes not only from synthetic fertilizers but also from uncontrolled or excessive transfer of organic load to soil

A relevant example: application of animal manure to land

Livestock farming in EU countries is subject to regulations aiming at limiting the environmental impact of nitrate discharge (Nitrate Directive)

Organic wastes: problem or opportunity?

Household organic wastes

Food industry residues

Animal byproducts

Animal manure and slurry

Crop residues Organic sludges

Green woody waste

easy solutions may be critical to the environment or not particularly energy efficient

Nature may help:

Anaerobic Digestion

- extracts the energy content in a methane rich biogas - prepares the remaining sludge to be recover as fertilizer and soil improver

AD: key process parameters

Temperture ( C) Resident times (days)

Effect of Anaerobic Digestion on organic matter

Before digestion

After digestion

Water

Water

Biodegradable Feedstock
Minerals Minerals Organics Organic s

Digestate

Organics

Along with woody residues, digestate sludge can be composted, i.e. AEROBICALLY digested, to produce a natural fertilizer and soil improver

The anaerobic-aerobic INTEGRATED approach to biowaste management

Integrated anaerobicaerobic bio-waste management:

100 tons
10-15 tons

the mass balance says the cycle is virtually closed

30-40 tons

30-40 tons

Anaerobic Digestion in practice

AD reactor

Feedstock

Biogas

Digestate

Combined Heat and Power production

AD: What goes in? What comes out?

Data from Danish studies

CO-DIGESTION: often the right receipt

A key issue: quality of feedstock

Chemical, biological and physical contamination of the feedstock is to be avoided to secure both biogas yield and digestate quality

How to design Anaerobic Digestion?

First questions when designing AD

The reactor feeding system is key to successful AD

Simplified Anaerobic Digestion

Single Phase Wet Anaerobic Digestion Process

SEMI DRY DIGESTION horizontal digester with horizontal paddle stirrer

Batch Anaerobic Digestion Processes

Dry Batch AD (Weiland, Rieger, Ehrmann, 2003)

Biogas power plant: Accumulation Continuous Flow (ACF)

Source: German Biogas Association

Completely stirred (CSTR), thermally isolated wet AD (thermophilic/mesophilic)

(source: Thoni)

Now or never: a look inside the digestor

Biogas: a good alternative to natural gas

Different options for biogas utilisation

Combined Heat & Power production: The State of the Art for biogas utilisation

A closer look to a CHP set

The fertilizing properties of the digestate

Organic nutrients prevail in the input feedstock

Whereas mineral nutrients prevail in the digestate

Digestate management starts with solid-liquid separation Raw digestate from AD

Fibrous fraction

Liquid fraction

Digestate S-L separation selectively partitions organic and mineral nutrients

Key economic elements of a biogas project

60 kWe biogas plant in Reggio Emilia, Italy

Cow manure 1387 ton/y - 27% TS

Cow slurry 3285 ton/y - 7% TS

Maize silage 438 ton/y - 38% TS

STORAGE, PRE-TREATMENTS, MIXING

60 kWe biogas plant in Reggio Emilia, Italy

Biodegradable feedstock 5110 ton/y 14,4% TS

ANAEROBIC DIGESTION

Raw biogas 314 ton/y 31 Ncm/h

BIOGAS CLEANING AND DRYING

5110 ton/y (14,4% TS) 271560 cm/y biogas (53 cm/ton) 57 kWe (11 kWe per 1000 ton/y) 117 kWe (23 kWt per 1000 ton/y)

Digestate 4796 ton/y 8,8% TS

LIQUID/SOLID SEPARATION Purified biogas 314 ton/y 31 Ncm/h

Solid digestate 1416 ton/y 25% TS

COGENERATION

Liquid digestate 3380 ton/y 2% TS

Power 57 kW 456 MWh/y

Heat 117 kW 935 MWh/y

STORAGE

STORAGE

HEAT RECOVERY SPREADING ON FARMLAND

Process power 16 kW 128 MWh/y

Dispatched power 41 kW 328 MWh/y

Recoverable heat 105 kW 840 MWh/y

Waste heat 12 kW 95 MWh/y

320 kWe biogas plant in Offlaga (BS), Italy

Bovine manure 527 ton/y - 27% TS

Bovine slurry 3644 ton/y - 9% TS

Swine manure 1374 ton/y - 23% TS

Swine slurry 3589 ton/y - 3% TS

Maize silage 4800 ton/y - 32% TS

STORAGE, PRE-TREATMENTS, MIXING

320 kWe biogas plant in Offlaga (BS), Italy

Biodegradable feedstock 13934 ton/y 17,4% TS

ANAEROBIC DIGESTION

Raw biogas 1542 ton/y 152 Ncm/h

BIOGAS CLEANING AND DRYING

13934 ton/y (17,4% TS) 1331520 cm/y biogas (96 cm/ton) 320 kWe (23 kWe per 1000 ton/y) 668 kWe (48 kWt per 1000 ton/y)

Digestate 12392 ton/y 7,2% TS

LIQUID/SOLID SEPARATION Purified biogas 1542 ton/y 152 Ncm/h

COGENERATION

Solid digestate 3370 ton/y 25% TS

Liquid digestate 9021 ton/y 2% TS

Power 320 kW 2560 MWh/y

Heat 668 kW 5343 MWh/y

STORAGE

STORAGE

HEAT RECOVERY
SPREADING ON FARMLAND

Process power 263 kW 458 MWh/y

Dispatched power 57 kW 2102 MWh/y

Recoverable heat 550 kW 4400 MWh/y

Waste heat 118 kW 943 MWh/y

990 kWe biogas plant in Fossano (CN), Italy

Agro-food industry sludges 5000 ton/y - 18% TS

Organic household wastes 27000 ton/y - 23% TS

Agro-food industry waste 3000 ton/y - 18% TS

Liquid digestate 24500 ton/y 0,5% TS

STORAGE, PRE-TREATMENTS, MIXING

990 kWe biogas plant in Fossano (CN), Italy

Biodegradable feedstock 54700 ton/y 11,7% TS

ANAEROBIC DIGESTION

Raw biogas 4695 ton/y 447 Ncm/h

BIOGAS CLEANING AND DRYING

54700 ton/y (11,7% TS) 3889440 cm/y biogas (71 cm/ton) 990 kWe (18 kWe per 1000 ton/y) 1632 kWe (30 kWt per 1000 ton/y)
Municipal sewage sludge 5000 ton/y 18% TS Woody waste 20000 ton/y 65% TS

Digestate 52705 ton/y 3,8% TS

LIQUID/SOLID SEPARATION

Purified biogas 4668 ton/y 444 Ncm/h

Solid digestate 22615 ton/y 20% TS

Liquid digestate 32984 ton/y 0,5% TS

COGENERATION

COMPOSTING

Power 990 kW 7920 MWh/y

Heat 1632 kW 13056 MWh/y

Compost 24455 ton/y 50% TS

Process loss

HEAT RECOVERY

Process power 705 kW 2611 MWh/y

Dispatched power 805 kW 7139 MWh/y

Process heat 813 kW 3952 MWh/y

Waste heat 819 kW 9104 MWh/y

Massimo CALZATI

WE CAN HELP MAKING A BETTER WORLD

THANKS FOR YOUR ATTENTION!!

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