ANAEROBIC DIGESTION ENERGY RECOVERY FROM BIO EFFLUENT, SLUDGE AND MIXED ORGANIC WASTE ENERGY RECOVERY FROM BIO EFFLUENT, SLUDGE AND MIXED ORGANIC WASTE
New Energy production is one of the four key businesses of Waterleau, next to water, air and waste treatment. Waterleau has acquired substantial know-how in the production of green energy from both organic and non-organic waste. Biogas from organic waste is obtained through anaerobic digestion, a series of processes in which micro organisms break down biodegradable material in the absence of oxygen hence producing biogas, a valuable energy source
NEW ENERGY
from wastewater from biomass from waste
aerobic wwt anaerobic wwt anaerobic digestion drying non toxic toxic
biogas biogas combustion recover & recycle
biogas
SOLUTIONS FOR GREEN ENERGY
Waterleau offers the complete range of anaerobic digestion technology, both wet anaerobic digestion (BIOTIM® WET AD) as dry anaerobic digestion (BIOTIM® DRY AD). For wet anaerobic technology WATERLEAU offers as wel thermophilic (BIOTIM® WET AD thermophilic) as mesophilic turnkey solutions (BIOTIM® WET AD mesophilic). The Waterleau BIOTIM® and LUCAS® reactor range includes solutions for the production of green energy from every concentration of organic waste and load:
Wastewater from food & beverage industry Concentrates from agro & food processing industry Sludge from municipal wastewater Bio waste Liquid and dewatered manure and chicken litter Slaughterhouse waste Energy crops; maize and grass silage Kitchen and restaurant waste (KRW) Organic fraction of municipal solid waste (OFMSW) Mixed bio waste
2 WATERLEAU ANAEROBIC REACTOR RANGE
The appropriate choice of the anaerobic reactor type depends on the composition of the organic waste. Choosing the appropriate anaerobic reactor for a specific organic effluent or organic waste is a key to success.
BIOTIM® UASB High volumetric loading rates can be reached in certain wastewaters. The BIOTIM® UASB (Upflow Anaerobic Sludge Blanket) reactor is the most commonly used system mainly because of its simplicity and robustness.
BIOTIM® UAT The UAT (Upflow Anaerobic Tower) technology can be applied on easily and fast biodegradable wastewater flows generated by the Food & Beverage industry or the chemical industry. Applying hydraulic loading rates between 18-25 kg COD/m³ per day, the UAT solution generates a reduction of the reactor volume up to 33% compared to a conventional reactor.
BIOTIM® UAC The BIOTIM® UAC (Upflow Anaerobic Contact) reactor is a hybrid reactor (combination of an UASB reactor with an AC process) for wastewater or concentrates that show no granule formation and/or require a longer hydraulic retention time than a UASB.
BIOTIM® CSTR The BIOTIM® CSTR is Waterleau’s Continuous Stirred Tank Reactor. This type of reactor is typically used for very concentrated waters or for waters rich in solids.
BIOTIM® Solids Waterleau’s BIOTIM® solids reactor is specially designed to treat sludge from municipal wastewater treatment plants. Sludge from both primary and secondary treatment is mixed and heated to accelerate biological conversion.
BIOTIM® WET AD Waterleau has designed a BIOTIM® wet AD reactor with appropriate pre-treatment for the treatment of organic waste with a high moisture content such as kitchen and restaurant waste, manure or energy crop.
BIOTIM® DRY AD The organic content of dry solids in mixed organic household waste is approximately 50% The BIOTIM® dry AD technology is specially designed to handle this type of waste successfully.
SETTING STANDARDS IN DIGESTER TECHNOLOGY
KITCHEN WASTE & MANURE
3-9 % DM 20-100 kg COD/m³
BIOTIM® UASB BIOTIM® UAT WATERLEAU UASB
+/- 1% DM 3-6 % DM
3 ANAEROBIC DIGESTION OF EFFLUENTS FROM THE INDUSTRY
The BIOTIM® and LUCAS® anaerobic wastewater treatment technologies are Waterleau’s flag-ship solutions for the production of biogas from bio-effluent. In combination with aerobic treatment, up to 99% from the effluent’s organic load can be removed, allowing the final effluent stream to be discharged safely or to be further treated for reuse purposes.
Waterleau offers turn-key solutions for anaerobic digestion in different industries:
Brewery industry Food & beverages Dairy industry Potato processing Sugar industry Bakery and yeast Agro-industry Chemical industry
BEET/SUGAR CANE VINASSES CHEMICAL INDUSTRY
Waterleau has designed and built an anaerobic treatment Waterleau’s daugther company KARY-PLANAQUA has plant for one of the largest producers of yeast and bakery designed and built the high rate anaerobic treatment plant at ingredients, capable of treating vinasses containing high levels Bitterfeld with a capacity of 40.000 kg COD/day. The Upflow of BOC, COD & TSS but also containing high concentrations of Anaerobic Tower (UAT) produces 1,2 MWe from high-loaded potassium, sulphates, nitrogen and bivalent ions. wastewater coming from the chemical industry. The anaerobic effluent is further treated in the municipal waste water The key to success of anaerobic treatment in this particular case treatment plant. is the spilt up between the biomass retention time and the hydraulic retention time: a BIOTIM® UAC reactor is followed by an external sludge separation system (SEPAFLOC®) with biomass recirculation. This solution combines the advantages of CSTR and UASB technology and excludes their potential drawbacks. Other advantages are the small footprint (up to 70% less space) and the lower anaerobic effluent TSS values, facilitating the aerobic post-treatment.
Mauri Hull, United Kindom Bitterfeld, Germany BIOTIM® UAC - Biogas: 14.344 Nm³/day BIOTIM® UAT - 10.400 Nm³ biogas /day
4 Heineken, Spain Tereos, France Biogas production: 9.600 Nm³/day Biogas production: 26.000 Nm³/day
WATERLEAU HAS DESIGNED AND BUILT MORE THAN 100 AD REFERENCES IN THE FOOD & BEVERAGE INDUSTRY
Heineken, The Netherlands Biogas production: 3.905 Nm³/day
Claerebout Waesten, Belgium Diageo Kumasi, Ghana Biogas production: 11.400 Nm³/day Biogas production: 3.200 Nm³/day
WATERLEAU COUNTS MORE THAN 400 REFERENCES IN THE ANAEROBIC TREATMENT OF INDUSTRIAL WASTEWATER
Castel, Togo Biogas production: 2.600 Nm³/day
5 ANAEROBIC DIGESTION OF SLUDGE FROM MUNICIPAL WASTEWATER
Sludge, the semi-solid material left over from the sewage treatment process must be treated and disposed of in a safe and effective manner. Next to sludge drying and incineration, Anaerobic Digestion is used for the degradation of the organic matter thereby reducing the sludge volume. The methane generation is a key advantage of the anaerobic process. The methane can be used in co-generators for producing heat and electricity.
WATER PRIMARY TREATMENT Water inlet
Screen
Oil & sand catcher SLUDGE BIOGAS ENERGY
SECONDARY TREATMENT Sedimentation Thickener Flotation Gas ow monitoring Cogeneration unit
Biological reactor tank Digester Desulphurisation Electric Thermal power energy
Clari er Dewatering Flare Boiler
Coagulation Sludge storage Flocculation To river
TERTIARY TREATMENT Sand ltration
UV
Chlorination Process MWTP Marrakech
ENERGY FROM SLUDGE IN FEZ AND MARRAKECH
In large wastewater treatment plants like Fez or Marrakech, the BIOTIM® AD technology allows the production of up to 70% of the plants energy needs while reducing the carbon footprint and greenhouse gas emissions. In both wastewater treatment plants, the cogeneration solution meets the CDM (Clean Development Mechanism) requirements of the Kyoto Protocol Office.
Marrakech, Morocco Fez, Morocco BIOTIM® solids - Biogas: 18.000 Nm³/day – Energy production: 1,8 MWe BIOTIM® solids - Biogas: 28.800 Nm³/day – Energy production: 3,2 MWe
6 Marrakech, Morocco 1,8 MWe
Fez, Morocco
3,2 MWe
Fez, Morocco
UP TO 70 % OF THE ENERGY NEEDS OF A WASTEWATER TREATMENT PLANT CAN BE PROVIDED BY SLUDGE DIGESTION
7 ANAEROBIC DIGESTION OF BIOMASS
YOUR PROJECT PARTNER FROM DEVELOPMENT TO CONSTRUCTION
Waterleau has developed proprietary technology for the production of biogas from organic waste. BIOTIM® WET AD (mesophilic as well as thermpohilic process designs) and BIOTIM® DRY AD are Waterleau’s anaerobic digestion solutions for the treatment of a wide variety of organic waste. Waterleau counts several references of organic waste treatment plants, each with a solution adapted to its specific types of organic waste.
Two other partners within the Waterleau Group offer additional expertise in organic waste treatment. IBH Consulting Engineers, a Waterleau company located near Brussels, relies on a track record of 30 years of expertise in feasibility studies, project management and operation of municipal waste management, including anaerobic digestion treatment plants. Kary-Planaqua, our Waterleau company located in Bremen, Germany, is also a provider of turn-key solutions for the treatment of biowaste. The combined expertise in the anaerobic digestion of wastewater and organic waste within the group, makes Waterleau a reliable provider of feasibility, consultancy and turnkey solutions.
FEASABILTY - TENDER & PROCESS MANAGEMENT - ENGINEERING CONSULTANCY
R&D - DESIGN & BUILD - OPERATION & MAINTENANCE
R&D - DESIGN & BUILD - OPERATION & MAINTENANCE
1 TON OF KITCHEN WASTE PRODUCES 120 NM3 OF BIOGAS
8 BIOTIM® WET AD: MESOPHILIC AND THERMOPHILIC
Waterleau has developed proprietary technology for the production of biogas from organic waste. BIOTIM® WET AD (mesophilic as well as thermophilic process designs) and BIOTIM® DRY AD are Waterleau’s anaerobic digestion solutions for the treatment of a wide variety of organic waste.
BIOTIM® WET AD DIGESTOR
BIOTIM® WET AD is available in both mesophilic and thermophilic process designs.
For the digestion of vegetable waste with a limited nitrogen concentration (≤ 3.000 mg NH4/liter), a thermophilic process design is a compact solution. The mesophilic process design is particularly adapted to operate under high concentrations of nitrogen, allowing digestion of organic waste mixtures composed of kitchen & resto waste, pig & cow manure, slaughterhouse waste, oil & fat, etc.
KITCHEN & RESTAURANT WASTE (KRW)
Waterleau offers different tailor made solutions for the treatment of kitchen waste.
Waterleau integrates the best solution for the waste pre-treatment. Different “blender & unpack” solutions make it possible to remove the packing material from the kitchen waste. Adding and mixing vegetable oil into the feed mixture help to maximize the biogas production or to separate and sell the oil.
Waterleau has experience with a wide range of combination’s of kitchen waste and manure.
MANURE & ANIMAL WASTE
BIOTIM® WET AD mesophilic offers the flexibility of treating different mixes of organic as well as animal waste types with a significant Nitrogen content such as : liquid pig manure, dewatered pig manure, dewatered cow manure, slaughter house waste, oil’s and fat’s kitchen waste, maize, grass silage..
BIOTIM® WET AD can optimize the incoming waste matrix to produce a maximum of biogas at a minimal feed stock cost :
BIOGAS PROTENTIAL NITROGEN BALANCE
FLOW BIOGAS POWER N total SUBSTRATES % DM %kWelec %N (tons/year) (Nm³/ton) (kWelec) (kg N/ton)
Liquid pig manure 17.520 7 33 144 5% 6,5 15% Dewatered pig manure 17.520 25 80 350 12% 11 26% Dewatered pig manure (fresh) 10.000 28 115 287 10% 13,4 18% (Dewatered) cow manure 10.000 20 75 187 6% 5,5 7% Kitchen waste 40.000 18 125 1.248 42% 4 21% Wheat rejects 5.555 65 400 555 18% 17 13% Fat, oil, glycerin 1.830 50 500 228 8% 1 0% INPUT MIXTURE 102.425 22 117 3.000 100% 7,3 100%
9 BIOTIM® THERMOPHILIC AD SOLUTIONS
BIOTIM® WET AD thermophilic technology (50 – 55°c operating temperature) is a recommended solution for organic waste with a low to moderate nitrogen concentration. With a 25 to 30 days residence time it’s quite a compact technology. In many
countries, thermophilic technology is also accepted as hygienisation. Thermophilic digesters range from 300 kWelec to 2 MWelec.
CASE: LORENZ SNACK-WORLD, GERMANY - MODERATE NITROGEN ORGANIC WASTE
Potato crisp waste and vegetable fat waste from potato crisp factories are particularly suited for the compact BIOTIM® WET AD thermophilic technology. The BIOTIM® WET AD thermophilic digestor at Lorenz Snack World operates on a combination of high fat content and low nitrogen level in this type of waste.
BIOTIM® WET AD thermophilic digester, residence time ~ 30 days
Cogeneration units with a capacity of 0,3 MWelec and 0,3 MWh. The green electricity and heat are re-used in the factory.
Capacity: 11.000 tpy - Biogas: 3.465 Nm³/day 0,3 MWe
LORENZ FLOW BIOGAS kW SNACK-WORLD (tons/year) (Nm³/ton) elec Potato waste 5.475 100 137 Potato peeling 5.475 100 137 Fat, oil 365 465 46 Dry organic waste 0 400 0 TOTAL 11.315 112 320
CASE: DE RESE, BELGIUM - SLAUGHTERHOUSE WASTE
Slaughterhouse waste is a very protein rich waste type. Its high nitrogen content can be toxic to anaerobic bacteria. Waterleau designed a smart process solution to overcome this problem. Pig rumen contents are mixed (50/50) with other biowaste in order ® to achieve an acceptable NH4 (ammonia) concentration in the BIOTIM thermophilic WET AD digestor.
BIOTIM® WET AD thermophilic digester, residence time ~ 30 days Cogeneration unit with 0,5 MWelec and 0,5 MW heat capacity. The green electricity and heat are re-used in the factory.
0,5 Capacity: 11.000 tpy - Biogas: 5.500 Nm³/day MWe
FLOW BIOGAS DE RESE kW (tons/year) (Nm³/ton) elec Concentr. organic 5.475 145 198 Pig stercoaric waste 5.475 120 164 Fat, oil 1.095 465 138 Dry organic waste 0 400 0 TOTAL 12.045 163 500
10 CASE: VALMASS, BELGIUM - MIXED BIOWASTE
Waterleau has built the Valmass BIOTIM® WET AD thermophilic & post treatment plant The combined mix of organic waste is ® suited for BIOTIM thermophilic technology. The overall NH4 (ammonia) concentration is acceptable ( ≤ 3 000 mg NH4/l ) .
BIOTIM® WET AD thermophilic
The BIOTIM® WET AD thermophilic digestor treats a variety of kitchen & restaurant waste, food waste mixtures, potato waste, oils & fats, etc. The total plant treats 80.000 tons/year and produces 1,7 MWelec or 14.000 MWhelec/year which is sold as green electricity to the grid.
BIOTIM® WET AD thermophilic digester, residence time ~ 30 days
2 cogeneration units of 850 kWelec each, the heat is reused in the dryer and evaporator BIOTIM® complete post treatment
BIOTIM® post-treatment
The solid fraction from centrifugation is further dried in a HYDROGONE® dryer into a valuable dry organic fertiliser, rich in phosphorous. The liquid fraction from centrifugation is biologically purified in a ATLANTIS® bio membrane reactor. After polishing in a EXSEL® RO treatment, the effluent complies with water discharge limits. The RO concentrate is further concentrated in an evaporator to produce a potassium rich fertiliser of 30 % DS which can be recycled for agricultural use. The dryer and evaporator make use of the heat, recovered from the CHP unit.
FLOW BIOGAS VALMASS kW Capacity: 80.000 tpy - Biogas: 19.000 Nm³/day (tons/year) (Nm³/ton) elec Kitchen waste 35.040 100 875 Onion waste 18.250 75 342 Potato waste 18.250 75 342 Fat, oil, glycerin 365 500 46 Dry organic waste 1.460 330 120 TOTAL 73.365 94 1.724
1,7 MWe
11 BIOTIM® MESOPHILIC AD SOLUTIONS
BIOTIM® WET AD mesophilic is particularly suited to treat a high variety of organic waste such as pig manure, cow manure as
well as waste with a high ammonia (NH4+) concentration. Mesophilic digesters range from 500 kWelec to 15 MWelec.
CASE: ODENDORF, GERMANY - MIXED BIOWASTE
Waterleau’s daughter company Kary Planaqua has built the turnkey biogas plant of Odendorf, which includes a BIOTIM® WET AD mesophilic digestor and post digestor. The BIOTIM® WET AD mesophilic plant treats 18.000 tons/year of pig manure, food waste and energy crops.
BIOTIM® WET AD mesophilic digester + post-digestor, residence time ~ 50 days
A 500 kWelec biogas CHP unit and digestate dewatering
Capacity: 18.000 tpy - Biogas: 6.200 Nm³/day 0,5 MWe FLOW BIOGAS ODENDORF kW (tons/year) (Nm³/ton) elec Pig manure 6.387 25 38 Dewatered pig manure 0 80 0 Food waste 1.825 145 63 Fat, oil 0 465 0 Dry organic waste* 10.220 180 436 TOTAL 18.432 123 537 (*) energy crop: maize, grass silage
CASE: LUSTADT, GERMANY - MIXED BIOWASTE
Waterleau’s daughter company Kary Planaqua has built the turnkey biogas plant of Lustadt, which includes 3 BIOTIM® WET AD mesophilic digestor’s and a post digestor. The BIOTIM® WET AD mesophilic treats 53.000 tons/year of pig manure, food waste and energy crops.
3 BIOTIM® WET AD mesophilic digester + post-digestor, residence time ~ 62 days Biogas pressure stations and digestate dewatering
Capacity: 53.000 tpy - Biogas: 23.570 Nm³/day
FLOW BIOGAS LUSTADT kW (tons/year) (Nm³/ton) elec Pig manure 6.570 30 47 Dewatered pig manure 3.650 80 73 Food waste 8.760 150 312 Fat, oil 2.190 465 277 2,0 Dry organic waste 32.120 180 1.371 MWe TOTAL 53.290 161 2.080 (*) energy crop: maize, grass silage
12 CASE: TETEROW, GERMANY - MIXED BIOWASTE
Waterleau’s daughter company Kary Planaqua has built the turnkey biogas plant of Teterow. The BIOTIM® WET AD mesophilic treats 46.000 tons/year of pig manure, food waste, grass silage, winter crop silages, energy crops (maize). The BIOTIM® WET AD plant produces 2 MWe or 16.000 MWh elec/year
3 BIOTIM® WET AD mesophilic digestor’s + post digestor, residence time ~ 72 days Biogas pressure stations and digestate dewatering.
Capacity: 45.660 tpy - Biogas: 24.000 Nm³/day
FLOW BIOGAS TETEROW kW (tons/year) (Nm³/ton) elec Grass silage 10.220 130 315 Winter crops 17.009 180 726 Wheat grain 1.825 500 216 Dry organic waste* 16.242 200 770 TOTAL 45.661 191 2.074 (*) energy crop: maize, grass silage
2,0 MWe
13 CASE: WATERLEAU NewEnergy YPRES, BELGIUM - MIXED BIOWASTE
Waterleau NewEnergy Ypres is an Anaerobic Digestion plant for the treatment of mixed biowaste. Waterleau not only designed and built but also operates the state-of-the-art AD plant.
MIXED BIOWASTE
Waterleau NewEnergy Ypres allows the treatment of mixtures of Kitchen & Restaurant Waste, liquid manure, dewatered manure, all kinds of organic waste and vegetable oil & fat waste
WTLNEI FLOW (tons/year) BIOGAS (Nm³/ton) kWelec Pig manure 17.520 30 131 1 TON OF KITCHEN Dewatered pig manure 17.520 80 350 Kitchen waste (1) 35.040 120 1.050 WASTE PRODUCES Kitchen waste (2) 21.900 130 711 120 NM³ OF BIOGAS Fat, oil, glycerin 3.650 500 456 Dry organic waste 4.015 400 401 TOTAL 99.645 125 3.098
PRE-TREATMENT
As packing material often accounts for up to 10-20% of kitchen waste mixtures, which is difficult to remove, a dedicated treatment prior to digestion is required. Waterleau proposes several sieving/blending and pulping solutions. The blender will allow to separate the plastic spoons and bags from the organic waste. The blended soup is then mixed with digestate and sieved. The sieved organic fraction is eventually pumped into the digester.
HYGIENIZATION OF ANIMAL BY-PRODUCTS
Hygienization (1 hour @ 70 °C) of the organic matter may be required to respect EU laws for sanitation. Especially when treating animal by-products, hygienisation can be integrated before as well as after the anaerobic digestion.
BIOTIM® WET AD DIGESTOR
The Waterleau NE plant is designed with a double stage BIOTIM® WET AD mesophilic system : main digestor + post digestor. After treatment, the biogas feeds the Combined Heat & Power (CHP) unit for the production of green electricity
(3 MWelec). The recovered heat is used to heat the digestor’s, dryer and evaporator.
POST-TREATMENT
HYDROGONE® complete post-treatment The remaining solid fraction from digestion and centrifugation is further dried into a valuable dry organic fertilizer, rich in phosphorous.
BIOTIM® POST TREATMENT The liquid fraction from centrifugation is treated in a completely covered BIOTIM® aerobic post treatment. The BIOTIM® aerobic post treatment removes TSS and all volatile organic carbon. The effluent coming from the aerobic treatment is evaporated using the heat of the CHP-unit, in order to produce 2 valuable fertilizer’s (1) : The Potassium (K) and phosphate (P) salts in the digestate are concentrated in the first evaporation step, producing a high value Potassium Fertiliser (K).(30 % DM). (2) : The condensates of the first evaporation step are sent to an ammonia stripper/scrubber to produce an ammonia sulphate or ammonia solution as Nitrogen (N) fertilizer. The clean effluent is discharged in surface water.
14 BIOTIM® WET AD FLOW SCHEME
3,2 MWe
15 CASE: DP WORLD, BELGIUM - KITCHEN & RESTAURANT WASTE
DP WORLD operates one of the largest multipurpose container terminals in the Port of Antwerp. The terminal requires large amounts of energy for the operation of gantry cranes, straddle carriers as well as the cooling of the fresh food containers. Committed to reduce carbon footprint, DP World has contracted NPG Energy, investor in green projects, to invest & operate a biomass-to-energy plant located next to the DP WORLD container terminal. DP WORLD targets to operate on 100 % green energy.
Waterleau has built the complete turnkey biomass-to-energy plant for NPG Energy using the BIOTIM® WET AD mesophilic technology. The BIOTIM® WET AD plant produces green energy out of 60.000 tons/year of a mix of organic waste ranging from kitchen & restaurant waste (food waste mix), vegetable fats & oils to a variety of concentrated organic waste products.
® The BIOTIM WET AD plant will produce 3 MWe or 24.000 MWHelec/year, (equivalent to the consumption of approx. 7.000 households). This green energy is used for the operation of the DP World container terminal.
PROCESS DESIGN: BIOTIM® Anaerobic dosing core : flexible reception and pre-treatment system for a wide variety of organic waste 3 BIOTIM® WET AD mesophilic digesters, residence time ~ 45 days BIOTIM® WET AD mesophilic post digester, residence time ~ 15 days 2 cogeneration units, each with a 1,5 MWe capacity and including the heat recovery system used for the drying of the digestate, the hygienisation and the heating of the digestor’s. Digestate drying plant to convert the digestate into valuable fertiliser, and making use of the heat of the CHP units MV grid connection
DP WORLD FLOW (tons/year) BIOGAS (Nm³/ton) kW elec Capacity: 60.000 tpy Kitchen & resto waste 29.200 125 934 Biogas: 30.000 Nm³/day Food waste mix 20.000 202 1.034 Fat, oil, glycerin 2.190 465 308 Maize 5475 195 273 Wheat rejects 3650 377 352 TOTAL 60.515 184 2.901
3,0 MWe
16 CASE: POTATO PROCESSING, BELGIUM - MODERATE NITROGEN ORGANIC WASTE
Waterleau’s has designed and built a BIOTIM® WET AD mesophilic digestor plant for the digestion of potato and kitchen & restaurant waste including a post treatment of the digestate.
The BIOTIM® WET AD mesophilic handles 100.000 tons/year of potato and kitchen waste.
BIOTIM® pre-treatment : BIOTIM® anaerobic soup/mixing system and hammer mill BIOTIM® WET AD mesophilic digestor, typical residence time ~ 38 days Heat and power generation in two CHP-units of 1.500 KWe each (the heat is reused in the factory (steam, hot water…..)) BIOTIM® complete post treatment : nitrification, denitrification and clarifier Biogas treatment : BELGAS® desulfurization, activated carbon treatment, biogas drying and compression
Capacity: 100.000 tpy - Biogas: 30.000 Nm³/day
FLOW BIOGAS kW (tons/year) (Nm³/ton) elec Fat, oil 3.650 465 462 Potato waste 45.625 100 1.243 Kitchen waste 47.450 100 1.292 3,0 MWe TOTAL 96.725 114 2.997
BIOTIM® WET AD MESOPHILIC SOLUTIONS FOR BIO-METHANE PLANTS
Kary Planaqua, a member of the Waterleau Group, is constructing one of the largest turnkey Bio Methane plants in Germany for RWE, including BIOTIM® WET AD mesophilic digestor and post digestor technology, as well as the Bio-methane purification plant.
The BIOTIM® WET AD mesophilic plant will treat 60.000 tons/year of manure, concentrated chicken manure and concentrated energy crops allowing the production of 7 MW of bio-methane.
3 BIOTIM® WET AD mesophilic main digestor’s (total capacity 12.000 m³) Capacity: 60.000 tpy Bio-Methane production plant : 700 Nm³/h
7,0 MW
17 BIOTIM® DRY AD
Waterleau has developed a BIOTIM® DRY AD solution for the treatment of Organic Fractions of Municipal Solid Waste (OFMSW). Its heterogeneous and seasonal composition requires a specific treatment.
MUNCIPAL SOLID WASTE ORGANIC FRACTION OF MUNICIPAL Due to the significant presence of garden waste (wood, soil, sand) and impurities, SOLID WASTE the organic content is limited to approximately 47% to 55% (on DS), versus 85 to 90% (on DS) for kitchen and restaurant waste. As a result, after a ‘natural’ anaerobic 40 to 50 % biodegradation, the remaining material (and anaerobic biomass) in the anaerobic digester is quite dry compared to wet AD systems: 25% DS up to 35% DS and behaves 47 to 55 % like a semi-dry pasta. The BIOTIM® DRY AD system is especially designed to handle 110 - 120 Nm³ OFMSW. biogas/ton
220 - 260 kWhelec / ton 330 - 400 kWh / ton PRE-TREATMENT therm
550 - 660 kWh / ton Energy production for therm The organic fraction of household waste is heterogeneous and contains impurities. 1.000 kW 40.000 tons/year elec An adequate pre-treatment to remove these impurities is necessary. The typical pre- to 1.200kWhelec treatment consists of a mechanical size reduction and an adequate screening to remove packing material. The oversize fraction contains most of the plastics, pieces Winter: wet & low of wood and big metal pieces. After pre-treatment, the sieved material is transported garden fraction to the heart of the system : the thermophilic BIOTIM® DRY AD digester. Very seasonal The thermophilic BIOTIM® DRY AD system is a 2-step system: the BIOTIM® Hydrolysis pre-digester is followed by the main BIOTIM® DRY digester.
A CITY OF 1.3 MILLION INHABITANTS PRODUCES 100.000 TONS OF ORGANIC FRACTION OF MUNICIPAL SOLID WASTE PER YEAR
AEROBIC COMPOSTING OF MSW CONSUMES ELECTRICTY DRY ANAEROBIC DIGESTION OF MSW PRODUCES 1 MWe FOR 40.000 TONS PER YEAR
18 BIOTIM® DRY AD FLOW SCHEME
BIOTIM® DRY AD DIGESTOR
The BIOTIM® hydrolysis reactor is equipped with a horizontal mixing/propulsing system. The screened input waste is mixed with recycled active anaerobic bacteria coming from the BIOTIM® DRY digester. The incoming waste receives a first hydrolysis step as preparation for the main BIOTIM® DRY digester. The substrate is turned into a homogeneous mass for easier pumping, reducing the required energy. BIOTIM® Hydrolysis pre-digesting guarantees higher flexibility. The mixing, hydrolysis and heating can be adjusted independently and externally from the main digester.
ADVANTAGES BIOTIM® DRY AD
1. FLEXIBILITY: SEASONAL FLUCTUATIONS In the summer, the OFMSW contains a high ‘wood & garden’ as well as a ‘grass’ fraction. These fractions are biodegrading slowly and tend to increase viscosity and dry solids. During winter, the grass and ‘wood & garden’ fraction is substantially lower. The overall % DS decreases in winter. In addition, it rains more in the winter, so if necessary, structure materials can be added.
2. ROBUSTNESS: VARYING DEGREE OF POLLUTION Even after pre-treatment, sand as well as smaller pieces of plastic and wood are present. The sand and remaining pollution are retained in the semi-dry anaerobic “pasta” and flow through to the system towards the output. The mixing, transportation and pumping systems are adapted in dimensions and material to handle this ‘pasta’.
3. STABILITY In general, the higher the sand, soil and garden fraction in the input, the higher the percentage of DS in the digester (between 22% and 35% DS in the reactor).
POST-TREATMENT
There are 2 options for post-treatment: 1. The semi-dry pasta coming out of the BIOTIM® DRY AD reactor can be mixed together with green waste (‘structure material’) to ensure the maturation of the biomass in an aerobic composting facility. 2. Or the semi-dry pasta coming out of the BIOTIM® DRY AD reactor can be dried in a Waterleau HYDROGONE® dryer and turned into a valuable dry organic fertilizer.
19 MORE THAN 400 REFERENCES IN ANAEROBIC DIGESTION
DESIGN PROTECTING THE 4 ELEMENTS ENGINEERING CONSTRUCTION OPERATION MAINTENANCE We all have the responsibility to handle our natural resources in a careful and sustainable way. Waterleau develops environmental technologies and offers sustainable solutions for water, air and waste treatment, as well as for energy recovery. As an EPC contractor and operator, Waterleau counts more than 1000 references for municipal and industrial clients around the world.
Nieuwstraat 26, 3150 Wespelaar (Leuven), Belgium t. +32 (0) 16 65 06 57 - f. +32 (0) 16 65 06 63 [email protected] - www.waterleau.com