integrated anaerobic digestion€¦ · dry anaerobic digestion is the system of choice for solid...

$: Integrated Anaerobic Digestion€¦ · Dry Anaerobic Digestion is the system of choice for solid organic fractions Industrially proven in Europe and capable to produce compost and$
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Integrated Anaerobic Digestion

Biogas Workshops, Parramatta & Gold Coast25 July and 2 Aug 2016 / Dr Marc Stammbach

Integrated Anaerobic Digestion

Organics, Compost and Methane

Income and Cost Streams

Overseas Experiences

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Organics, Compost and Methane

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Towards a “circular economy”State-of-the-art waste management framework

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(2) (3)(1)

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Why organics recycling with Anaerobic Digestion (AD)?Closing the nutrient cycle while generating energy

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Typical biogas yields:- Green waste: ~ 80 Nm3/t- Kitchen waste: ~ 180 Nm3/t- OF MSW: ~ 150 Nm3/t

Typical biogas yields fromAustralian feed stocks:- Mango peals: ~ 450 Nm3/t- Banana peals: ~ 280 Nm3/t- Orange peals: ~ 460 Nm3/t- Sugar cane bagasse: ~ 380 Nm3/t

Kompogas® dry ADDesigned for a large variety of input materials

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Householdbio-waste

Green waste

Organic fraction ofMSW / residual waste

Market andvegetable waste

Catering andkitchen waste

Expired foodfrom supermarkets

Organic waste stream changes over time => requiring a “future-proof” system !

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Kompogas® dry ADThe continuous plug-flow digester of the market and technology leader

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Horizontalplug flow

Thermophiletemperature

Single shaftagitator

Internalinoculation

Input

Discharge

BiogasDM: 20-50%

DM: ~30%

DM: 25-30%

Biogas to Biomethane

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Biomethane = attractive alternative to fossil fuel1 Nm3/a biomethane = ca. 1 litre diesel fuel

HZI membrane technology HZI amine scrubbing technology

Upgrading technologies available (HZI in-house)Amine washing=> high purity: up to 99.5%=> methane slip: <0.1%=> pressure: near atmosphericMembrane=> pressure: up to 16 bar=> small foot-print=> no heat required

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Produce your own CNG or renewable diesel

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Biomethane = attractive alternative to fossil fuel1 Nm3 biomethane = ca. 1 litre diesel fuel20,000 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- SC Bagasse: ~ 380 Nm3/t 4.3 Mio litres diesel/y

Income and Cost Streams

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Business case subject to country, organic stream, size & local conditions

Income streams:Disposal cost = Gate-fee for waste(landfill levies, low odour in-vesselprocesses, acceptance of organic bin)Biogas = renewable energy (electricity,heat, steam, Biomethane, BioCNG,BioLNG)Carbon dioxideRenewable benefits (ERF, RECs) –nice to have, but not bankableCompost (from negative to plus)Liquid fertilizer with nutrients (fromnegative to plus)

Cost drivers:Community consultation, Env.ImpactStatement, Development ApprovalCapital (reactor, upgrading, balance ofplant)Work Health Safety functionsMaintenance cost24/7 automation and staffPre-treatment of organics & post-treatment of outputs (composting, de-watering, storage)Marketing and transport to marketEnergy unless produced internallyATO compliance cost for BioCNG forroad use (small, no excise benefit likein Europe)

Overseas Experiences

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Our experience – the first

Location: Rümlang / CHCommissioning: 1991

Throughput: 8`500 Mg /a

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Terni, Italy

l Partial stream Kompogas process bypassing 40% of material for mixing withdigestate - no liquid digestate is generated

l Very high gas yield of 170 Nm3/t mainly coming from FORSUl Turnkey project including composting plant supplied by Cesaro Mac Import with sub-supply

of Kompogas core module digesterl 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

Client Terni Energia / Cesaro Mac.Start-up 2012

TechnologyPlant type Biowaste plantInput material FORSU* & green wasteDigester type PF1300-1 concrete/steel digesterBiogas usage CHP

Technical DataPlant Capacity 17`500 Mg/aBypass Material 10’000 Mg/aBiogas production 2`400`000 Nm3/aElectricity production 4`920`000 kWh/aCHP installed: 1 x 700kWelSolid digestate 16`500 Mg/aLiquid digestate -

* Frazione Organica del Rifiuto Solido Urbano

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Rijesenhout, Netherlands

l Partial stream Kompogas® process (patented), hence no liquid digestatel Biogas upgrading to 99,5%CH4 content and grid injectionl CO2 capturing while biogas upgrading and reuse in neighbouring greenhousesl Use of condensate water from composting tunnels for street cleaning and surplus heat for

neighbouring greenhousesl On site CNG fuelling station for Meerlanden’s own garbage trucks

Client Meerlanden Holding eVStart-up 2010

TechnologyPlant type Biowaste plantInput material GFT (green & kitchen waste), greaseDigester type PF1300-2 concrete/steel digesterBiogas usage Biomethane & grid injection

Technical DataPlant Capacity 48`000 Mg/aBiogas production 2`600`000 Nm3/aBiomethane production 12`200`000 Nm3/aEnergy content 12`200`000 kWhSolid digestate 40`000 Mg/aLiquid digestate 5`000 Mg/a

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Winterthur, Switzerland

l Another Kompogas® dry AD plant with high level of automationl EPC turnkey contract for complete plant, incl. civil worksl Standardized steel digester with nominal volume of 1500m3

l Biogas is upgraded and injected into the gas grid (upgrading by Amine washing technology)

Client Kompogas® Winterthur AGStart-up 2014

TechnologyPlant type Biowaste plantInput material Comingled green and food wasteDigester type PF1500 steel digesterBiogas usage Biomethane & grid injection

Technical DataPlant Capacity 23`000 Mg/aBiogas production 1`800`000 Nm3/aBiomethane production 1’000`000 Nm3/aSolid digestate 11`800 Mg/aLiquid digestate 11`400 Mg/a

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Integration of Kompogas® plug-flow digesters into Biowaste(Source Segregated Organics, SSO) or MBT plants (Organic Fraction of MSW, OFMSW)

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Backnang-Neuschönta / Germany (SSO)

Fulda / Germany (SSO) Doha / Quatar (OFMSW & SSO)

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Doha, Qatar

l Large integral waste processing plant combining mechanical sorting, Kompogas® dry ADand thermal energy from waste of residual solid waste

l Largest Kompogas® dry AD plant in the world with 15 x PF1300 concrete digestersoperating in parallel (12 x OFMSW + 3 x green waste)

l Main driver for dry AD: production of compostl Biogas usage in Combined Heat and Power (CHP) plant

Client Ministry of Municipality & UrbanPlanning

Start-up 2011

TechnologyPlant type Integrated MSW Management CentreInput material MSW / Organic Fraction of MSW,

green wasteDigester type 5xPF1300-3 concrete digesterBiogas usage CHP

Technical DataPlant Capacity 840’000 Mg/a (AD: 274’000 Mg/a)Biogas production 24’200`000 Nm3/aElectricity production 56`900`000 kWh/a

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Montpellier, France

l Largest AD plant in Europe, being integral part of an MBTl High impurity content in organic fraction sorted from MSWl High energy yield: in average 140 Nm3 of biogas per metric ton input materiall Dewatering system with centrifuge and subsequent water treatment plantl Full-fledged composting plant, using tunnels and covered windrowsl Odour treatment with water/acid scrubbing system, fully enclosed biofilter and activated

carbon

Client Montpellier AgglomérationStart-up 2008

TechnologyPlant type MBT plantInput material MSW / Organic Fraction of MSWDigester type 4 x PF1300-2 concrete digesterBiogas usage CHP

Technical DataPlant Capacity 203’000 Mg/a (AD: 105’000 Mg/a)Biogas production 14’400`000 Nm3/aElectricity production 30`000`000 kWh/aSolid digestate 28`000 Mg/aLiquid digestate none

May 2016 - Latest Market HighlightBologna is largest AD project currently under execution in Europe

What?REAL circular economySource separated biowaste will be anaerobically digested with Kompogas®

Where?Italy – Bologna

Who?HERAmbiente – Integrationin existing composting plant

How?100’000 tpy biowaste4x Kompogas® PF1800 digesters30’000 tpy quality compost> 14’000’000 Nm3 biogas / year

By whom?Cesaro Mac & HZI in cooperation

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ProprietaryTechnology

from HZI

Engineeredby HZI

Managed by HZI

Project Management

Electrical and Control TechnologyBalance of Plant

Energy Use

Feeding System Digester Discharge System Dewatering

Site and Building Services Engineering

IntegratedSolution

MaximizedEfficiency

ReliableExecution

Basis of our Success in Anaerobic Digestion:First-Class Technology and Turn-Key Capabilities

Summary

Application:Dry Anaerobic Digestion is the system of choice for solid organic fractionsIndustrially proven in Europe and capable to produce compost and renewable energy(electricity, BioMethane, BioCNG and BioLNG)Not locally proven and requires support

Strategic fit:Closes nutrient, carbon and fuel cycleFits in with Australian organic waste strategiesBest if used with internal energy consumer / “off the grid” or to produce CNG

Affordability:Turn-key delivery of proven systems (but also bankable)Interesting potential for tropical food wastes and bagasseScale matters$0/t for high biogas yielding feed stocks to $80-$120/t urban organics based onreliable & high biogas production

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Waste is our Energy.Engineering is our Business.Sustainable Solutions are our Mission.

Check our References

Kompogas® plant referencesWe deliver - we keep promises - check our references

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Selected Kompogas® AD references

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Fulda, Germany

l EPC turnkey contract for complete plant, incl. civil worksl Biogas green energy park: dry AD combined with wet anaerobic digestion of food wastel Biogas is collected from both dry and wet AD plants and upgraded to gas grid qualityl Process heat supplied by woodchips boilerl Full use of liquid and solid fertilizer, thereby closing nutrient cycle 100%

HZI Kompogas® AD references

Client Biothan GmbHStart-up 2013

TechnologyPlant type Biowaste plantInput material Comingled green and food wasteDigester type PF1300-2 concrete/steel digesterBiogas usage Biomethane & grid injection

Technical DataPlant Capacity 32`000 Mg/aBiogas production 3`000`000 Nm3/aEnergy content 24`000`000 kWh/aSolid digestate 16`000 Mg/aLiquid digestate 11`000 Mg/a

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Faedo, Italy

l Partial stream Kompogas process (patented) and hence no liquid digestate is generatedl Very high gas yield of 160 Nm3/t mainly coming from FORSU - would allow to install

additional CHP (permit limited to 1MWel)l Turnkey project including composting plant supplied by Cesaro Mac Import with sub-supply


cycle 100%l Main drivers for project: gate fee for FORSU and production of electricity


Client Bioenergia Trentino / Cesaro Mac.Start-up 2012


Technical DataPlant Capacity 32`000 Mg/a (40’000 Mg/a)Mixing material 16’000 Mg/aBiogas production 3`800`000 Nm3/aElectricity production 7`800`000 kWh/aSolid digestate 29`000 Mg/aLiquid digestate -


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Angers, France

l Integral waste processing plant using mechanical sorting and Kompogas dry ADl High impurity content in organic fraction sorted from MSWl Full-fledged composting plant, using tunnels and enclosed refinement boxesl Odour treatment with water/acid scrubbing system, fully enclosed biofilter and activated

carbonl Biogas usage in Combined Heat and Power (CHP) plant

Client Angers Loire MétropoleStart-up 2012

TechnologyPlant type MBT plantInput material MSW / Organic Fraction of MSWDigester type 2xPF1300-2 concrete digesterBiogas usage CHP



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Botarell, Spain

l EPC delivery of AD plant incl. intermediate storage, automatic feeding and dewateringsystem

l High impurity content in organic fraction sorted from MSWl High energy yield: in average 160 Nm3 of biogas per metric ton input materiall Dewatering system with centrifuge and subsequent water treatment plantl Full-fledged composting plant, using composting tunnels

Client Baix Camp Serveis ComarsalsMediambientals SA

Start-up 2010

TechnologyPlant type MBT plantInput material MSW / Organic Fraction of MSWDigester type PF1300-3 concrete digesterBiogas usage CHP

Technical DataPlant Capacity 100’000 Mg/a (AD: 54’000 Mg/a)Biogas production 6`500`000 Nm3/aElectricity production 15`300`000 kWh/aSolid digestate 42`000 Mg/aLiquid digestate none


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Passau, Germany

l Integration of Kompogas dry AD system into an existing composting plant, doubling theplant’s throughput capacity

l Located close to living areas (requiring sound odour control) and a riverl High efficient CHPl Full use of liquid and solid fertilizer, thereby closing nutrient cycle 100%l Uninterrupted operation for more than 10 years with high performance


Client Abfallzweckverband DonauwaldStart-up 2004

TechnologyPlant type Biowaste plantInput material Comingled green and food wasteDigester type PF950-3 concrete / steel digesterBiogas usage CHP

Technical DataPlant Capacity 40`000 Mg/aBiogas production 4`200`000 Nm3/aElectricity production 11`500`000 kWhSolid digestate 18`000 Mg/aLiquid digestate 15`000 Mg/a

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Zurich, Switzerland

l Typical Swiss Kompogas dry AD plant, with pit bunker reception and high automation levell EPC turnkey contract for complete plant incl. civil worksl Located close to living areas (requiring sound odour control) and a riverl Biogas is upgraded and injected into the gas grid, enough to heat 3’000 homesl Full use of liquid and solid fertilizer, thereby closing nutrient cycle 100%l First Kompogas steel digester PF1500 delivered to private client


Client Biogas Zürich AGStart-up 2014


Technical DataPlant Capacity 25`000 Mg/aBiogas production 2`100`000 Nm3/aBiomethane production 1`200`000 Nm3/aEnergie content 12`000`000 kWhSolid digestate 10`000 Mg/aLiquid digestate 12`000 Mg/a

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Backnang, Germany

l Typical German Kompogas dry AD plant, with flat bunker reception and high level ofautomation

l EPC turnkey contract for complete plant incl. civil worksl Use of excess heat capacity for waste water treatment sludge dryingl Full use of liquid and solid fertilizer, thereby closing nutrient cycle 100%


Client AWG Rems-Murr-Kreis mbHStart-up 2012

TechnologyPlant type Biowaste plantInput material Comingled green and food wasteDigester type PF1300-2 concrete/steel digesterBiogas usage CHP

Technical DataPlant Capacity 36`000 Mg/aBiogas production 4`300`000 Nm3/aElectricity production 10`200`000 kWh/aCHP installed: 2 x 800kWelSolid digestate 10`000 Mg/aLiquid digestate 15`000 Mg/a

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Rostock, Germany

l First MSW Kompogas dry AD plant in Germany, increasing throughput capacity of existingMBT plant

l Partial stream digestion, thereby no liquid digestatel In-vessel composting system for digestate, with stabilized product combusted in nearby

incineration plant (mixed-waste compost not allowed on land in Germany/Europe)l Very high energy yield: in average 180 Nm3 of biogas per metric ton input materiall Biogas is upgraded and injected into the gas grid, in addition to CHP


Client EVG / VeoliaStart-up 2007

TechnologyPlant type MBT plantInput material MSW / Organic fraction of MSW,

food wasteDigester type PF1300-3 concrete/steel digesterBiogas usage CHP & Biomethane

Technical DataPlant Capacity 135’000 Mg/a (AD: 40’000 Mg/aBiogas production 7`200`000 Nm3/aElectricity production: 10`200`000 kWh/a (2 x 625kWel)Biomethane production 300 Nm3/h

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Winterthur, Switzerland

l Typical Swiss Kompogas dry AD plant, with high level of automationl EPC turnkey contract for complete plant, incl. civil worksl Standardized steel digester with nominal volume of 1500m3

l Biogas is upgraded and injected into the gas grid (upgrading by Amine washing technology)


Client Kompogas Winterthur AGStart-up 2014


Technical DataPlant Capacity 23`000 Mg/aBiogas production 1`800`000 Nm3/aBiomethane production 1’000`000 Nm3/aSolid digestate 11`800 Mg/aLiquid digestate 11`400 Mg/a

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Weurt, Netherlands

l Partial stream Kompogas process (patented), hence no liquid digestatel Lean gas from biogas upgrading process is re-injected into the digester – no loss of CH4

l Capturing of CO2 from biogas upgrading for commercial usel Synergies with adjacent incineration plant (heat for digesters, combustion of exhaust air,

incineration of sieved-out impurities, etc.)


Client ARN B.V.Start-up 2012

TechnologyPlant type Biowaste plantInput material GFT (green & kitchen waste)Digester type PF1300-2 concrete/steel digesterBiogas usage Biomethane & grid injection

Technical DataPlant Capacity 38`000 Mg/aBiomethane production 320 Nm3/hCO2 production 2`500 Mg/aSolid digestate 30`000 Mg/aLiquid digestate -

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Montpellier, France

l Largest AD plant in Europe, being integral part of an MBTl High impurity content in organic fraction sorted from MSWl High energy yield: in average 140 Nm3 of biogas per metric ton input materiall Dewatering system with centrifuge and subsequent water treatment plantl Full-fledged composting plant, using tunnels and covered windrowsl Odour treatment with water/acid scrubbing system, fully enclosed biofilter and activated

carbon

Client Montpellier AgglomérationStart-up 2008

TechnologyPlant type MBT plantInput material MSW / Organic Fraction of MSWDigester type 4 x PF1300-2 concrete digesterBiogas usage CHP

Technical DataPlant Capacity 203’000 Mg/a (AD: 105’000 Mg/a)Biogas production 14’400`000 Nm3/aElectricity production 30`000`000 kWh/aSolid digestate 28`000 Mg/aLiquid digestate none


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Rijesenhout, Netherlands

l Partial stream Kompogas process (patented), hence no liquid digestatel Biogas upgrading to 99,5%CH4 content and grid injectionl CO2 capturing while biogas upgrading and reuse in neighbouring greenhousesl Use of condensate water from composting tunnels for street cleaning and surplus heat for

neighbouring greenhousesl On site CNG fueling station for Meerlanden’s own garbage trucks


Client Meerlanden Holding eVStart-up 2010

TechnologyPlant type Biowaste plantInput material GFT (green & kitchen waste), greaseDigester type PF1300-2 concrete/steel digesterBiogas usage Biomethane & grid injection

Technical DataPlant Capacity 48`000 Mg/aBiogas production 2`600`000 Nm3/aBiomethane production 12`200`000 Nm3/aEnergy content 12`200`000 kWhSolid digestate 40`000 Mg/aLiquid digestate 5`000 Mg/a

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Novi, Italy

l Full stream Kompogas process with screw press and decanter recirculating 8% of decanterfirst stage output liquids

l High gas yield of 140 Nm3/t mainly coming from FORSUl Project was integrated in existing plant supplying digestion, CHP and dewatering system as

EPC by Cesaro Mac Import with sub-supply of Kompogas core module digesterl Full use of solid and liquid digestate to close nutrient cycle 100%l Main drivers for project is gate fee for FORSU and production of electricity


Client SRT Spa / Cesaro Mac.Start-up 2012


Technical DataPlant Capacity 18`000 Mg/aBiogas production 1`900`000 Nm3/aElectricity production 3`900`000 kWh/aCHP installed: 1 x 700kWelSolid digestate 3`500 Mg/aLiquid digestate 14’800 Mg/a


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Vetroz, Switzerland

l Typical Swiss Kompogas dry AD plant, with high level of automationl EPC turnkey contract for complete plant, incl. civil worksl Located close to living areas (requiring sound odour control) and a riverl Decantation of press water to reduce amount of liquid fertilizerl Biogas is upgraded and injected into the gas grid (upgrading by Amine washing technology)


Client GazEI SAStart-up 2014

TechnologyPlant type Biowaste plantInput material Comingled green and food wasteDigester type PF1300 concrete/steel digesterBiogas usage Biomethane & grid injection

Technical DataPlant Capacity 20`000 Mg/aBiogas production 1`900`000 Nm3/aBiomethane production 900`000 Nm3/aSolid digestate 13`000 Mg/aLiquid digestate 4`000 Mg/a (decanted)

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Doha, Quatar

l Large integral waste processing plant combining mechanical sorting, Kompogas dry ADand incineration systems

l Largest Kompogas dry AD plant in the world with 15 x PF1300 concrete digestersoperating in parallel (12 x OFMSW + 3 x green waste)

l Main driver for dry AD: production of compostl Biogas usage in Combined Heat and Power (CHP) plant

Client Ministry of Municipality & UrbanPlanning

Start-up 2011

TechnologyPlant type Integrated MSW Management CentreInput material MSW / Organic Fraction of MSW,

green wasteDigester type 5xPF1300-3 concrete digesterBiogas usage CHP



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Forbach, France

l Biowaste plant receiving source segregated food/kitchen waste (in coloured plastic bags,optically sorted with a spiral system) and green waste

l Dewatering system with sieve-screw pressesl Press-cake maturation and composting in tunnels, use of liquid fertilizer in nearby

agriculture, thereby closing nutrient cycle 100%l A part of the biogas is upgraded to CNG quality and injected into the gas grid, the

remainder is used in a CHP plantl Own CNG fueling station on site for SYDEME’s own garbage trucks

Client SYDEME(Syndicat Mixte de Transport desDéchets de la Moselle Est)

Start-up 2012

TechnologyPlant type Biowaste plantInput material Comingled green & food wasteDigester type 3 x PF1300 concrete digesterBiogas usage CHP, biomethane & grid injection

Technical DataPlant Capacity 42’000 Mg/aBiogas production 5’500`000 Nm3/aBiomethane production 400’000 Nm3/aElectricity production 10`900`000 kWh/aHeat production 12’400’000 kWh/aSolid digestate 8`000 Mg/aLiquid digestate 10’000 Mg/a


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Terni, Italy

l Partial stream Kompogas process bypassing 40% of material for mixing withdigestate - no liquid digestate is generated

l Very high gas yield of 170 Nm3/t mainly coming from FORSUl Turnkey project including composting plant supplied by Cesaro Mac Import with sub-supply


cycle 100%l Main drivers for project is gate fee for FORSU and production of electricity


Client Terni Energia / Cesaro Mac.Start-up 2012


Technical DataPlant Capacity 17`500 Mg/aBypass Material 10’000 Mg/aBiogas production 2`400`000 Nm3/aElectricity production 4`920`000 kWh/aCHP installed: 1 x 700kWelSolid digestate 16`500 Mg/aLiquid digestate -


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Contact details:

Dr. Marc [email protected]+61 2 8003 4110

integrated anaerobic digestion€¦ · dry anaerobic digestion is the system of choice for solid...

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