Download - Laetitia d'Ursel - Waterleau Anaerobic Digestion Case studies - Waste Expo & Conference 2014
WIN-WIN:
FROM ORGANIC WASTE TO ENERGY RECOVERY
CASE STUDIES: CO-DIGESTION, FOOD WASTE & ORGANIC MUNICIPAL SOLID WASTE
From wastewaterFrom sludgeFrom biomassFrom biosolidsFrom waste
CLEAN ENERGY
Chemical pollutantsDesulphurization
DedustingVOC and odour control
(Bio)gas cleaning
Soil remediationHazardous waste
Municipal wasteIndustrial wasteSolids & sludge
Drinking waterProcess waterWastewaterDesalinationWater reuse
CLEAN AIR
CLEANING UP WASTE
WATERLEAU: 1500+ REFERENCES IN 82 COUNTRIES
CLEAN WATER
Environmental Process Engineering – Design Build Operate
47 Technologies & 30 Patents - Own Equipment Manufacturer
WASTE MANAGEMENT & MINIMIZATION STRATEGY
Thermal:
Combustion, Gasification, Pyrolysis
Biological:
Anaerobic Digestion
Landfill:
Landfill gas recovery
Disposal
Energy Recovery
Recycle / Compost
Reuse
Minimisation
Prevention
Biological:
Anaerobic Digestion
WASTEWATER
FOOD & BEV
CONCENTRATES
OF BIO
FACTORY
MWWTP
SLUDGE
POTATO
WASTE, MAIZE,
MIXED
BIOWASTE
KITCHEN &
RESTAURANT
WASTE
ORGANIC
FRACTION OF
MSW
WATERLEAU ANAEROBIC DIGESTION FROM A TO Z
% DM in
reactor
% DM Input
Kg COD/m³
3-10% DM 2-8% DM 3-4,5% DM 7-12% DM 8-12% DM 25-35% DM
Biogas
Nm³/T80 80 20-30 110 120 - 130 110 - 120
2-20 kg
3-9% DM
2-20 kg
5-7% DM
50-70 kg
15-20% DM
150-200 kg
15-35% DM
150-250 kg
35-50% DM
150-200 kg
Reactor
types
UASB
UATUAC Solids
Wet AD
CSTR
Wet AD
CSTRDry AD
� PRIMARY ADVANTAGES:
� Reduce volume of organic waste� Obtain a clean end product� Produce green energy (electricity, hot water & steam)
� SECONDARY ADVANTAGES:
� Pathogen destruction
� Pre-treatment for nutrient recovery
� Reduction of odors
� Reduced greenhouse gas emissions
� Conversion to more available N (N to NH3).
� Improved flow properties
� Improved fertilizer efficiency
ANAEROBIC DIGESTION AS A BIOLOGICAL SOLUTION TO TREAT WASTE
RENEWABLE ENERGY
DIGESTATE TREATMENT: FERTILIZERS & CLEAN WATER
HIGH
QUALITY
FERTILISER
HIGH
QUALITY
FERTILISER
BIOGAS
PRE-
TREATMENT
PRE-
TREATMENT
ANAEROBIC
DIGESTOR
ANAEROBIC
DIGESTOR
DRYINGDRYING
COMPOSTINGCOMPOSTING
RESIDUERESIDUE
WATER
TREATMENT
WATER
TREATMENT
ORGANIC
WASTE
ORGANIC
WASTE
AIR/ODOUR TREATMENT
CLEAN WATERCLEAN WATER
ANAEROBIC DIGESTION PROCESS AND ITS END PRODUCTS
SOLIDS
TREATMENT
SOLIDS
TREATMENT
DESULPHURIZATION
CLEAN
BIOGAS &
ENERGY
WATER
REUSE
WATER
REUSE
SPLIT-UP
DIGESTATE
WATER
&
SOLIDS
SPLIT-UP
DIGESTATE
WATER
&
SOLIDS
HIGH
QUALITY
FERTILIZER
HIGH
QUALITY
FERTILIZER
WASTEWATER
FOOD & BEV
CONCENTRATES
OF BIO
FACTORY
MWWTP
SLUDGE
POTATO
WASTE, MAIZE,
MIXED
BIOWASTE
KITCHEN &
RESTAURANT
WASTE
ORGANIC
FRACTION OF
MSW
ANAEROBIC DIGESTION FROM A TO Z
% DM in
reactor
% DM Input
Kg COD/m³
3-10% DM 2-8% DM 3-4,5% DM 7-12% DM 8-12% DM 25-35% DM
Biogas
Nm³/T80 80 20-30 110 120 - 130 110 - 120
2-20 kg
3-9% DM
2-20 kg
5-7% DM
50-70 kg
15-20% DM
150-200 kg
15-35% DM
150-250 kg
35-50% DM
150-200 kg
Reactor
types
UASB
TowerUAC Solids
Wet AD
CSTR
Wet AD
CSTRDry AD
CASE 1 - MIXED BIOWASTE
CO-DIGESTION
CASE 2 – FOOD WASTE
BIOENERGY FROM BIOMASS – CASE STUDIES
DP World Port of Antwerp
(Marine terminal operator )
60,000 Tons/year
200 Nm³biogas/T
1,370 Nm³ biogas/h
3 MWe
WTL New Energy Ypres
(Bioenergy production plant)
120,000 Tons/year
105 Nm³ biogas/T
1,400 Nm³ biogas/h
3,2 MWe
7,7 MWth
SABMiller
(Brewery)
3.000 m³/d
10.500 kg COD/d
4.200 Nm³ biogas/d
6 MWth
CASE 3 – ORGANIC
FRACTION OF MSW
Intradel
(Municipal waste company)
25,000 Tons/year
1 MWe
CASE1: WTLNEI - ATOMIC VIEW
H2O, C, N, P, K
C (CH4)
H2O
NPK
WTL New Energy Ypres – Belgium : 3,2 MWe - 7,7 MWth
120,000 TPY bio-wastePig & Cattle Manure, Chicken litter, Crops, Slaughterhouse and Food & Restaurant waste
CASE1: WTLNEI – INPUT MIXTURE
Input ton/year
Pig Manure
Solid (dehydrated) manure
Restaurant Waste
Chicken Litter
15.000
20.000
2.000
INPUT MIXTURE: ORGANIC WASTE + MANURE
Organic Waste 20.000
Energy Crops 20.000
35.000
15%
34,3%
14,7%
19,6%
2%
19,6%
Dry Matter
25%
15%
50%
20%
33%
9%
BiogasNm³/ton
Nm³/hour
25
110
200
200
200
40
247
173
157
247,6
49,4
493,8
Biogas %
11,3%
19,5%
3,5%
35,5%
17,7%
12,4%
Ng N/kg
%
5
2,5
24
4
3
7
6
46
14
9
9
15
TOTAL 102.000 100% 111 1392 100% 5,18 100
CASE 1: WTLNEI – PROCESS FLOW DIAGRAM
Two types of digestors Biogas CHP
Liquid fraction - wastewater treatment
Solid fraction treatment
Pre-treatment
Organic
waste
CASE 1: WTLNEI – PRE-TREATMENT
• Mixing & liquidifying
with blender – pulper
Sieving
Package &
overflow waste
• Removing pollutants
through Sieving
• Hygienisation:
• < 12 mm pulp
• 1 hour @ 160 °F
CASE 1: WTLNEI – WET ANAEROBIC DIGESTION & POST DIGESTION
Anaerobic Digestion:
• 2 x 4.000 m³
• HRT 40 days
• Reactor type: CSTR
• Mesophilic
• 70% biogas generation
Post Digestion:
• 2 x 2.200 m³
• HRT 13 days
• 30% biogas generation
CASE 1: WTLNEI – DESULPHURIZATION & COGENERATION UNIT (CHP)
Desulphurization & Cogeneration (CHP):
• 7.7 MW thermal energy
• Input 1,400 Nm³/h
• 3.2 MWelec
• 1.5 MWth Steam
• 2.5 MWth Hot Water
CASE 1: WLTNEI – HYDROGONE® DRYING
Indirect Dryer:
• Input 22 % DM
• Output 12,000 TPY @ 90 % DM
• 1.5 MW Steam
• 1.8 TPH H2O evaporation
CASE 1: WTLNEI – ACTIVATED SLUDGE CONTACT STABILIZATION PROCESS
Wastewater Treatment:
• Input 15 m³/h
• Input COD 20.000 mg/l
• Output COD 10.000 mg/l
CASE 1: WLTNEI – EVAPORATOR
Evaporation Unit:
• Input 15 m³/h
• Recuperation of a 15%
ammonium solution
Ammonia
fertilizer solution
Potassium
Fertilizer
Process water
CASE 2 – FOOD WASTE
BIOENERGY FROM BIOMASS – CASE STUDIES
DP World – NPG Energy
(Marine terminal operator )
60,000 Tons/year
200 Nm³biogas/T
1,370 Nm³ biogas/h
3 MWe
CASE 2: DP WORLD - FOOD WASTE
TOTAL USA MSW DISCARDS 2011 – 164 Million Tons
(AFTER RECYCLING & COMPOSTING)
U.S. Environmental Protection Agency (EPA) (2013) Municipal Solid Waste Generation, Recycling, and
Disposal in the United States: Facts and Figures for 2011.
35 Million Tons/ Year
CASE 2: DP WORLD - FOOD WASTE
60,000 TPY WASTE - 3 MWE FOR CONTAINER HANDLING/ COOLING
CASE 2: DP WORLD - FOOD WASTE - WET AD FLOWSHEME
Solid
Waste
Liquid
Fertiliser
Macerator /
Pump
Storage
Tank
Solid
Fertiliser
WET AD 15 days
Post Digestor
BIOGAS to
CHP Units
Liquid
waste
Hygienisation
Solid Dosing
Soup tank
WET AD
50 days
Main Digestor
Screw press
Digestate
Biogas
Stones, Metal
Belt Dryer
Active Carbon
Polishing
Heat Exchanger
Electricity
CASE 2: DP WORLD - FOOD WASTE
WET AD: Organic Industrial Waste + Expired Food Waste
Capacity 60,000 tons/year - 200m³ biogas/T - 3 MWel
CHP units
Pre-
Treatment
Storage
TanksWet AD
Liquid
digestate
� ��
�
Wet AD
Post Digester
� �Dryer
�
CASE 2: PRE-TREATMENT: DOSAGE / MIXING / FEEDING
Dosing unit
solid waste
Soup tank
Blending/mixing
Hygienisation
Cogen : 3 MWe
CASE 2: ANAEROBIC DIGESTORS
DIGESTORS
- 3 main digestors (99,000 ft³/each)
- 1 post digestor (87,400ft³)
- 12%DM in digestors
TOP MIXER (11kW)
to counter the floating layer caused by :
- Glycerine
- Wheat
- Biomix(Soap stock)
CASE 2: BIOGAS COST EFFECTIVE DESULPHURISATION
STEP 1:
AIR INJECTION IN ROOF
Air injection in biogas membrane:
- Input: 1,000 ppm H2S
- Output 100 – 200 ppm H2S
STEP 2:
FINAL POLISHING/ABSORPTION
WITH ACTIVE CARBON
Output: << 50 ppm H2S
CASE 2: COGENERATION UNIT - GENSET : 2 X 1,5 MWE
BIOGAS MOTORS (2) :
- 3.65 MW biogas to Motor (100%)
- 1.50 MW elec (42% efficiency)
- 0.65 MW exhaust gas (18%)
- 1.02 MW hot water (28 %)
All heat recuperated for dryer,
hygienisation and digestion
BIOENERGY FROM BIOMASS – CASE STUDIES
CASE 3 – ORGANIC
FRACTION OF MSW
Intradel
(Municipal waste company)
Study for dry AD
25,000 Tons/year
1 MWel
CASE 3: ORGANIC FRACTION OF MSW - DRY ANAEROBIC DIGESTION
CASE 3: ORGANIC FRACTION OF MSW - DRY AD – 25,000 TON/YEAR – 1 MWEL
hydrolysis
Blender
Dosing
ShredderMagnetic Separator
Storage
area
DRY AD
Acceptance
Hall / pre
treatment
Cogen unit
Dryer
Air treatment
Biofilter
THANK YOU
Global office - Belgium
T +32 16 650 657 F +32 16 650 [email protected]
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M +1 (714) 727 7607 [email protected]
