From Pilot to Full Scale Operation of a Waste-to-Protein Treatment Facility Christian Zurbrügg, Bram Dortmans, Audinisa Fadhila, Stefan Diener Just one slide on the rationale Waste management is still a challenge in low income settings Organic solid waste is 50-80% of waste mass and is yet hardly recovered and recycled Strategies and policies are more and more including aspects of circular economy Current organic waste recovery/recycling still faces a «value chain» challenge Compost typically has limited value and customers are not where the product is Biogas often suffers from cheap energy competition Char production (or biomass fuel) is promising but limited to dry materials How else can we create value from waste? Lohri C.R., et al. (2017). Treatment technologies for urban solid biowaste to Possibilities create value products – a review with focus on low and middle income settings. Reviews in Environmental Science and Bio/Technology. 16/1, pp 81–130. P H Y S I C O - T H E R M O – B I O L O G I C A L D I R E C T C H E M I C A L C H E M I C A L T R E A T M E N T U S E T R E A T M E N T T R E A T M E N T T E C H N O L O G I E S P R O C E S S E S Direct Direct Com‐ Vermi‐ Black An‐ Fer‐ Trans‐ Lique‐ Direct Densi‐ Pyro‐ Gasifi‐ land animal post‐ compost‐ Soldier Fly aerobic men‐ esteri‐ fact‐ com‐ fication lysis cation application feed bustion ing ing treatment digestion tation fication ion P R O D U C T S Gly‐ Worms Resi‐ Digest‐ Pellets/ due ate cerol briquettes Bio‐ethanol Bio‐ Bio‐ Compost Larvae Biogas Char Gas diesel oil Meat/fish Crops Transport Cooking fuel/ production production fuel heat/electricity Animal husbandry Agriculture Bio-energy E N D – U S E Black Soldier Fly, Hermetia illucens Eggs Larvae feed on organic material • Fruits & vegetables Creates • Food waste Mating Young larvae value from • Slaughterhouse waste • Chicken manure waste • Human faeces Adult fly Larvae Conversion of 1 ton of food ~1 month waste into 250 kg fresh larvae Good substitute within 12 days • Fishmeal • Soymeal Pupae Prepupae Larvae contain ~40% protein and ~30% fat Material reduction of 70-85% dry matter Engineering BSF Engineered life cycle Waste treatment Control over: Waste treatment requires • # prepupae a steady mass production • # eggs of small larvae • # flies • 5‐DOL production Engineering of the • Survival rate • Retention rate life-cycle • Development time • … Pilot facility: Surabaya, Indonesia Engineering BSF Post-processing BSF Costing BSF Costing BSF (1 t/day) Activity Unit Euro/Year % of total Rearing units 31% Labour 2483 Scaling to x5 without much addition Consumables 1095 Annual equipment costs 1526 Other units 56% Labour 4966 Scaling will require some automation Consumables 881 Annual equipment costs 3545 $ Indirect costs 2174 13% Total 16’670 100% Labour 45% Consumables 12% Equipment 30% t/d Challenges Waste-derived products Waste Sourcing BSF Treatment Technology & markets Nursery Treatment Cherry-picking or solving Quality control! public challenges? Multiple revenue streams! BSF research conducted Sustainability aspects Economy Technology implementation • Time-motion-studies Pilot facilities • Economy of scale Process engineering • Sweden: optimization of • Development of business models Life cycle rearing facility • Feeding substrates Environment • Reproduction cycle • Indonesia: treatment of MOSW •LCA • Greenhouse gas emissions Operation • Circular economy (integrated • Waste treatment technology • Tanzania: fish feed systems) • Rearing facility production from fruit waste Education/Dissemination Product safety • Beginners Guide • Health risks (pathogens, heavy • MOOC-Module metals, pharmaceuticals) • Post-treatment options BSF - LCA 120 Life cycle analysis study in Indonesia Fishmeal transp. 100 Fishmeal prod. Methods Results 80 BSF: Other Composting: Energy • Measurement of CH4 and • Direct GHG emissions 60 BSF: LPG N2O during BSF treatment significantly lower for BSF 40 BSF: Electricity • Comparison with other than composting 20 GWP [kg CO2/ton waste] Composting: Direct emission organic waste treatment • Electricity consumption and 0 BSF: Direct emission technologies (composting) source of electricity most OVERALL GWP ‐20 relevant for LCA BSF larvae composting Standard composting Treatment option Conclusions 113’000 views .