uk ad & biogas 2016: day one green seminar- 6 july

UK AD & BIOGAS TRADESHOW

6-7 JULY 2016NEC BIRMINGHAM

LAND USE – GETTING EVERYTHING WE NEED: FOOD, FUEL AND FIBRECHAIR: TOM BEELEY, RENEWABLE ENERGY ADVISER, CLA

DR. CARLA TURNER, POLICY RESEARCHER, POLICY AND ECONOMICS, ADAS UK

GUY HILDRED, FARMER, GREENGASOXON

JOHN BURGESS, MAIZE PRODUCTION MANAGER, KWS UK

FOLLOWED BY OPEN DISCUSSION

Impacts of bioenergy maize cultivation on agricultural land rental prices and the

environment

www.adas.uk

ADAS and Ricardo [email protected]

www.adas.uk

• Spatial modelling of land rental values found no significant influence of proximity to AD plants

• Plant case studies captured a trend of rising land rental values but was inconclusive in the attribution

Environmental impacts of growing maize for AD

Land rental value impacts

• Unlikely to be any impact on drinking water quality for nitrate, suggesting that the impact on water quality is likely to be localised

• The 4 case studies have highlighted significant variation in the environmental impact of maize cropping for AD according to scale, location and management

• Mitigation strategies for reducing the environmental impact of maize cropping involve cover cropping and soil management techniques.

Guy Hildred, Farmer, GreenGasOxon

Energy Crops Update from KWS – 2017

KWS UK | 2016/17

Development of Energy Crop Usage

80

64 10

201112,000 ha

70

10

137

201645,000 ha

55

12

25

8

202555,000 ha

Energy Maize

Energy Beet

Other

Energy Hybrid Rye

-

Total effect of AD Cropping on Mainstream UK Area: > 1.5%2016 – approx. 210 on farm AD plants (based on crops)

Development of Energy Crop Usage

-

Gas to Grid CHP

Source: http://www.biogas-info.co.uk/resources/biogas-map (June 2016)

Farm structure Feedstock / digestate logistics Average field size Yield performance Soil type/ rainfall Radiation Blackgrass density

Stable area – 2016/17 ca. 45,000 ha 27,000 ha maize 17,000 ha rye 1,000 ha beet Beet Pulp Grass Silage Manures / Slurry

Future Challenges for UK on farm AD

-

Irrigation & Intercropping

Source: KWS


Increased drought pressure;

Light land farms Irrigation / abstraction restrictions Search for “drought tolerant” hybrids

Planting depth Shorter drilling windows

Further criteria on field margin / companion cropping

Insect pollinating crops on field margins (eg; sunflowers)

Companion cropping GHG measurements on farm inputs

-* Source: DLG, 2009

Rhizoctonia trials

* Source: DLG, 2009 Source: KWS


Tighter rotations in the Eastern Counties;

Rhizoctonia build up from beet & maize Fusarium build up from wheat & maize

KWS & BBRO research; 2016 initial field trials for Rhizoctonia

KWS working with existing AD plants; Monitor field yields Dry matter and gas yields Digestate analysis and applic. timing

-

Service Tools from KWS

-

Service tools from KWS

Seed Rates Soil Temp Heat Units

Enter farm postcode

Drop down menu to recommend hybrids

Live Heat Unit + Soil Temperature Tools

-

Enter your postcode

Data shows the soil temperature at 10 cm, for the 5 closest weather stations to your farm

Surface temperature is also shown, to highlight the risk of frost

Soil temperature has a strong effect of

early growth, up until the 4 to 5 leaf stage.

Soil Temperatures + Seed Rates

-

Hybrid Rye

-

Key Benefits of Hybrid Rye for Biogas

Introduced into the UK for biogas in 2010 2010: 500 ha total 2012: 2500 ha total 2014: 9500 ha total 2016: 12,000 ha est.

Easy to manage feedstock – spreads summer workload

Competitive yields on all soil types – 35 – 50 t/ha freshweight

Ideal complement to maize, grass or slurry in the biogas plant

Offers greater use of existing silage clamp area during the summer

-

2013 Season: – Day of Harvest – 10th July 2013

-

KWS MAGNIFICOKWS PROGAS

Added benefits for blackgrass control

Hybrid Rye will out compete Black-grass in the Autumn

Black-grass development within hybrid rye will be poor with later maturity (less light and nutrient availability) and reduced populations

Successive cropping in heavily infested fields will help reduce the seedbank over time

Black-grass in wheat plots

Black-grass in Rye plots

-

Thank you for your attention.

Land Use – Getting everything we need: Food, fuel & fibre

Tom BeeleyCLA Renewable Energy Adviser

Soil health

Price volatility of both outputs & inputs

Pest, weed & disease control

Compliance with regulation

Environmental needs

Sustainable intensification

Pressures on land use

Gas yield

Soil conditions, soil type, topography, climatic conditions

Logistically how will the crop integrate with the wider farming business?

Which crops will deliver the most additional benefit?

Achieving the sustainability criteria

What to consider when selecting crops?

Voluntary Guidelines on Best Practice

Questions and comments from the floor

LAND USE – GETTING THE MOST OUT OF YOUR CROP ROTATIONS ON YOUR FARMCHAIR: INNES MCEWAN, HEAD OF FARMING, FUTURE BIOGAS

OLLIE KNOWLAND, FARM ADVISOR, FUTURE BIOGAS

STEPHEN BRIGGS, INNOVATION FOR AGRICULTURE

LORENZO MAGGIONI, CIB


Chair: Innes McEwan, head of farming, future Biogas

Ollie Knowland, farm Advisor, Future biogas

UK AD & Biogas 2016… Land use seminar…..Getting the most from the rotations on your farm

Existing problems

- 45 years of “chemical farming”

- Short rotations

- Lack of diversity

- Pest and weed proliferation

- Declining soil health

What is AD?

A biological process:

The GHG Target

Feedstock Transport Storage AD Process Biomethane

34.80gCO2/MJ RHI £

Farming Benefits of AD

Rotational diversification

• Combining food and energy profitably and sustainably

• AD crops fit around vegetable and roots without ILUC issues

• Very marginal land can grow grass / maize / hybrid rye for AD

• Contribution to biodiversity may be easier than in conventional arable rotation

• Opportunities to grow cover crops to increase SOM reduce erosion

Farming Benefits of AD

Rotation rotation rotation!• Too much vegetable and arable cropping leads to:

• Weed burden and herbicide resistance (blackgrass, weed beet etc.)• Pest proliferation (PCN/BCN/Aphids)• Increased use of sprays and fertiliser• Depleted soils

Biomass for AD delivers new rotation opportunities• Alternative biomass options for AD bring biodiversity, soil improvement and

wildlife benefits• Wildflowers, whole-crop hybrid rye, perennials and high energy grasses• ELS/HLS grassland can be harvested to produce energy – double benefit!• AD biomass in rotation allows biofumigation (sustainable nematocide

alternative)Diversification

• Stable, local and long-term supply relationship at transparent pricing• Combining food and energy profitably and sustainably• Very marginal land can grow grass/maize/wildflowers for AD• Contribution to biodiversity may be easier than in conventional arable

rotation

So what can I grow?

The Classics

• Maize• Wholecrop Rye• Sugar Beet• Grass

The Novelties

• Wildflower Mixes• Power grass • Perennials

Source – Introduction to Bioenergy, KWS

Cattle Slurry Pig Slurry Poultry manure Organic waste Sugar Beet Maize Silage0

20

40

60

80

100

120

140

160

180

200

25 27

80

120

158

185

Gas yields of different feedstocks

Feedstock

Biog

as y

ield

per

tonn

e of

feed

stoc

k (m

3/t)

Wastes Crops

Energy Yields

Maize – It’s got lots going for it….

Maize offers a number of farming benefits, particularly to growers who need a sustainable break crop.

• It can be flexibly placed in the rotation and requires only a short growing window• Lengthening the rotation prevents vegetable or arable monocultures• Late lifted beet and vegetables often have no viable following crop• Maize grows well on poor land (as a C4 plant it uses water and nutrients very efficiently)• Maize in rotation helps meet C7, C9, C12 and C13 objectives from Campaign for Farmed Environment. • Large root structure provides soil fertility and can improve soil structure and increase organic matter. • Diversification on lighter land and where other crops have left the rotation (beet, veg, etc)

Maize – It’s got lots going for it….

Wholecrop Rye

Good for UK• Suits areas with insufficient heat for maize• Fast tillering – reduce soil erosion and run-off• Early harvest (late June/early July)

Good for Farms• Flexible drilling window• Good second cereal – “Wheat-Rye-Rape”• Suitable for stronger soils• Helps smother weeds• Good resistance to Take All, Eyespot and

Rabbits!• Rotational opportunities

FB 2013 Rye Crop!

BeetPros• Varieties of beet have been developed specifically

for biogas production and can outperform maize in terms of energy yield.

• Beet is easily digested improving processing time. • Beet can be easily integrated into conventional

biogas crop rotations whilst offering a higher tonnage output per hectare than maize.

Cons• Performance• Handling costs• Storage problems

Other Crop Options

Grass• Grass is suited to areas in the UK with above

average rainfall and where permanent pasture is common.

• Several perennial high yield varieties are coming to the market. Alternatives such as red clover mixes with ryegrass are also an attractive option as a biogas feedstock.

• Westerwold followed by maize but need irrigation

Other Grass• Szarvasi perennial wheatgrass• Useful on really poor outlying fields.• Low input area for liquid digestate• Improve SOM

Other Crop Options

Feedstock… quality is key

ClampingDry matter

Crop quality

The weather affects maize

Maize growing in the UK

• Do your research• Plan you harvest very carefully

• Join the MGA get independent advice• Use the MGA Recommended Maize variety booklet 2016 • MGA Site & Maturity Group Selector

25-Apr

30-Apr5-M

ay

10-May

15-May

20-May

25-May

30-May

4-Jun

9-Jun14-Ju

n19-Ju

n24-Ju

n29-Ju

n4-Ju

l9-Ju

l14-Ju

l19-Ju

l24-Ju

l29-Ju

l3-A

ug8-A

ug

13-Aug

18-Aug

23-Aug

28-Aug

2-Sep7-Sep

12-Sep

17-Sep

22-Sep

27-Sep0

500

1000

1500

2000

2500

3000

3500

2006200720082009201020112012201320142015Average

Cum

ulati

ve H

eat U

nits

Crop heat units – 10 Year Average – Buxton, Norfolk

3 of the last 4 years have been under

the 10 year average

Cumulative heat units – 1800 – 3000 OHU - Buxton

2-Aug

4-Aug

6-Aug

8-Aug

10-Aug

12-Aug

14-Aug

16-Aug

18-Aug

20-Aug

22-Aug

24-Aug

26-Aug

28-Aug

30-Aug

1-Sep3-Sep

5-Sep7-Sep

9-Sep

11-Sep

13-Sep

15-Sep

17-Sep

19-Sep

21-Sep

23-Sep

25-Sep

27-Sep

29-Sep1800

2000

2200

2400

2600

2800

3000

3200

Cumulative Heat Units - Buxton - 2006, 2012 - 2015 & 10 Year Average - 1800 to 3200 Heat Units

20062012201320142015Average

Cum

ulati

ve H

eat U

nits

2012, 2013 and 2015 have been 9-

10 days behind hot -test years and 5

days behind the av-erage

Further information

Digestate

AD Digestate – The Cow of the East?

Solid digestate

• 20-25% Organic matter

• Good level of nutrients

• Spreadable through out the year and stackable in field

• Year 1 nutrients= £5.20/t

Liquid digestate

• High level of readily available Potash

• Good source of available nitrogen

• Biologically active

• A balanced plant feed

• Year 1 nutrients = £5/m3

Liquid digestate uses

• Starter fertiliser for OSR

• Establishing cover crops

• Maize grown on 100% digestate

• Sugar Beet

• Topdressing Rye/Wheat

Nutrient Cycle

80% Nutrients recycled

Farmer A

Applying digestate

Feeding Plant

60% Liquid Digestate

20% Solid Digestate

Gas Production

20% Methane & Co2

Crop Production

Digestate use – Norfolk example

Field name Size (ha)

Cover Crop Variety Yield

Solid digestate

(t/ha)

Liquid digestate (m3/ha)

Total available N

(kg/ha)Previous crop Notes

Arnold 9 14.89 Mixed Fabregas 49.48 - 29.00 45.00 Rye & digestate Starter fert & top dressingCopplestone 1 4.63 Francisco 58.93 49.50 - 57.00 Rye & digestate Starter fert & top dressingCopplestone 2 1.78 Francisco 45.92 49.50 - 57.00 Rye & digestate Starter fert & top dressingCopplestone 3 5.65 Francisco 52.88 49.50 - 57.00 Rye & digestate Starter fert & top dressingCopplestone 5 4.54 Francisco 48.66 - 50.00 110.00 Rye & digestate Starter fert ONLYSSE 1 10.93 Franki 43.89 53.00 - 62.00 Spring barley Starter fert & top dressingSSE 3 6.27 Franki 42.33 51.00 - 59.00 Sugar beet Starter fert & top dressing

• Digestate applied to previous & current crop

• Yields well above average

• Digestate tracker & calculator• Plan digestate use in advance• Access to nutrient breakdown & value

Arnold 9

Copplestone 1

Copplestone 2

Copplestone 3

Copplestone 5

SSE 1SSE 3

-

10.00

20.00

30.00

40.00

50.00

60.00

70.00

Average yields where digestate applied

Questions

Innovative AD feedstock crop options for soil managementStephen BriggsSoil & Water Manager6 July 2016

June, 20165

6

6 July, 2016

Footer text here

57

Soil Management

Growing under plastic

Intro

No-till

Maize

Companion croppingRotations

Alternative crops

Soil Management

June, 2016 Footer text here5

8

Rotations


9

Maize

6 July, 2016 Footer text here6

0

Widely spaced crops

Exposed soil over winter

Late harvest in wet

conditions

Run-offLeachingCompacti

onPoor

infiltration


1

Growing under plasticEarly maturing varieties under plastic -> earlier harvest (September):• Better weather conditions• Less risk of compaction• More time to establish cover

crop

Welsh trials (Farming Connect):• Shorter growing season• Higher yield• Higher starch content

Companion crop


2

Maize undersown with companion crop: • Greater root mass promotes biological

activity and improves soil structure• Reduces N leaching by 25-40%

relative to monoculture (Zavattaro et al., 2012)

• Legumes (clover, vetch) increase available N and boost yield (Kramberger et al. 2014)

• Improved weed controlUK trials (Reaseheath College) begun 2016: maize undersown with grass, clover, vetch, peas and other legumes.

Undersowing maize


3

• Maintaining companion crop – shade ?• Yield penalties from using grass (ADAS trials) ?


4

Undersow in previous crop

Strip Till / Direct Drill


5

No-till maize


6

European research:• Improved infiltration / soil water (Cociu,

2015; Amaral et al., 2013)• Reduced run-off & erosion (Amaral et

al., 2013)

UK trials:• UK Maize Growers Association trials –

no-till soils too slow to warm • Defra-funded ADAS/North Wyke trials

conclude this year…

Alternative feedstock crops ?


7

Clover

GrassLucerne

Cereals (Rye/triticale)

Cover Crops


8

Barley Rye Triticale

Lucerne / Alfalfa

Alternative feedstock crops - biogass yield performance ?


9

• Cutting time influences methane yield

• Silage = Higher methane yields in cereals/maize

• Fresh = higher methane yield in lucerne

• Cereals can be comparable to maize

• Alfalfa/Lucerne can be comparable to cereals & Maize

Fresh Matter (FM) Silage (S)


0


1

Any [email protected]

BIOGASDONERIGHTAND SOIL CARBON SEQUESTRATION

The Italian efficiency model for

decarbonization of the agricultural sector

Lorenzo Maggioni- R&D CIB – Italian Biogas Consortium

SOME BASICS QUESTIONS

• Why producing Bioenergy with the current conventional farming, that emitsas much and the transport sector?

• Why producing energy crops, even if „no food“, occupying land whereas need for Food & Feed?

• Can the production of Bioenergy reduce emissions of conventional farming, turning farming and agroforestry from a problem to part of the solution?

• How can the Biogas refinery speed up a cost-effective penetration of intermittent renewables in the energy market and produce biomaterials and biochemicals?

IPCC MITIGATION REPORT 2014

Agriculture alone is responsible for 12% of the GHGs emission globally

WHEN WE PRODUCE RAPESEED BIODIESEL, NOTHING CHANGES AT THE FARM LEVEL

To lower emissions from agriculture we need:1. Mitigate emission from agroresidues and

wastes2. Keep the soil covered all year round, thus

increasing photosynthesis and rotations3. Increasing soil fertility via greater crop

residues, manuring and digestate applications

4. Disturb the soil as low as possible, via minimum tillage, strip tillage, sod seeding, precision farming and increased rotations techniques

5. Lower fossil inputs in fertilization and energy use, via organic fertilization, nitrogen fixing crops, biogas and biomethane in agriculture mechanization

LET DECARBONIZE CURRENTAGRICULTURAL PRACTICES (2)

6. Improve Nitrogen Usage Efficiency (NUE) via increased organic fertilization, drip irrigation with digestate liquid fraction , cover crops, etc.

7. Increased Net Primary Production (NPP) via increased Water Usage Efficiency (WUE) applying drip irrigation, CAM plants where C3 & C4 crops give marginal yields, increased field capacity thanks to soil greater organic carbon content ad its water buffering capacity

8. Lower pesticides and Plant Protection Products inputs, direct seeding on cover crops, increased organic fertilization, increased pollinator insects and increased biodiversity

BIOMASSES OF THEBIOGASDONERIGHT

• Livestock effluents• Agroresidues and agrowastes• Cover crops before or after cash crops• Food or perennial crops to revegetate

abandoned lands, where C3 and C4 are not farmed anymore, among these Cactaceae, alfalfa, perpetual meadows

BIOGASDONERIGHT IS HIGHLYEFFICIENT AND EASILY SCALABLE

• Biomethane is the key for thefuture energy mix

• Renewable and sustainable• Flexible, programmable• Allows integration Gas and

electricity grid• With Power to Gas stabilizes the

electricity grid

• Target for2030: 8 billions Nm3 BioCH4/year with an ecological agricultural intensification

Link

http://www.consorziobiogas.it/Content/public/attachments/630-2015%2012%2004_Position%20Paper%20of%20CIB%20-%20Snam%20-%20Confagri_%20ENG.PDF



SOIL CARBON SEQUESTRATION:IT WORKS, IT IS EASY AND CHEAP

• Soil can sequester Carbon atthe Gton scale needed

• Continous fertilization via manure increase soil Carbon content

• Can we sequestrate Carbonin soil via digestate? Yes!

LONG TERM EXPERIMENTS (> 20YEARS) TELL US IS HAPPENING

• N0: unfertilised test• N3: mineral fertilisers (urea and

superphosphate, recommended N and P input)

• C1: composted biosolids at rate 1• 7.5 Mg DM ha-1 yr-1 until 1994, 5

Mg DM ha-1 yr-1 onward, except the last three years (from 18 to 21) when the application rate was based on nitrogen (170 kg N ha-1 yr-1)

• C2: composted biosolids at rate 2• 15 Mg DM ha-1 yr-1 until 1994, 10

Mg DM ha-1 yr-1 onward, except the last three years (from 18 to 21) when the application rate was based on nitrogen (340 kg N ha-1 yr-1)

• composted biosolids are a mixture of dewatered sludge and wheat straw, 9:1 w/w respectively, turned for 2 months in an open platform and left for a further 1-1.5 months Paolo Mantovi – CRPA 2016 unpublished personal communication

#14pour1000 !!

BIOGASDONERIGHT: SOMETHINGMORE THAN A BIOENERGY

The Anaerobic Digestor infrastructure isable to revolutionize the farming practice:• It allows the soil to be covered the whole

year• It increases the rotations• It turns agrowastes into a precious

resource• It improves the WUE and NUE at the

farm

• It turns the farms from carbon emitter to a carbon sink

BIOGASDONERIGHT CAN BE DEPLOYED AT ANYLATITUDE AND ANY AGRICULTURAL CONDITIONS

VISION FOR THE FUTURE:BIOGAS REFINERY

• Integration of natural gas and electricity grid

• Production of renewable & organic fertilizers

• Production of biochemicals and biomaterials

• Mitigation of emissions

Our aim: an integrated biorefinery distributed on the territory that brings circular economy at the farm level

BIOGASDONERIGHT AND SOIL CARBON SEQUESTRATION

AD

MONOCROPS

DOUBLE CROPPING

LIVESTOCK MANURE

ORGANIC WASTES

ORGANIC FERTILIZERS

MEAT/MILK/EGGS

CEREALS

OTHER CROPS

FEED

RAW BIOGASCHILLE

RCHP

HEAT

POWER TO GRID (CAPACITY PREMIUM)

METHANATION UNIT

PEM ELECTROLYZER

H2

SOLAR PV

GRID

POWER TO GAS

UPGRADING

LIQUEFA CTION LNG

STORAG E

L-CNG FOR TRANSPORT

POLIMERIZATION UNIT

BIOPLASTI C

REFINERY

BIOPLASTIC

BIOMASS

BIOGAS REFINERY1. BIOGAS TO POWER 2. POWER TO GAS

3. BIOCH4 TO LNG 4. BIOCH4 TO PLASTIC

BIOGAS REFINERY: A FLEXIBLE, DISTRIBUTED MULTIPURPOSE PLANT

BIOMASS A

BIOMASS B

BIOMASS CBIOGAS PLANT

CO2

ENERGY

FERTILIZERS

OTHERS

ALGAE

POWER TO GAS

EMISSION FREE CAR

BIO CH4 BIOPLASTIC S

HEAT

LIQUID

SOLID

BIOCHAR

ELECTRICIT Y

BIOMASS…

BIOGAS REFINERY

• Wind and PV are becoming always cheaper

• Their share on the energy mix is increasing

• How to have a spare capacity, interconnect gas and electricity grid and stabilize intermittent energy sources? With distributed biogas refineries

Source: Bloomberg

NEXT CHALLENGE:STORAGE OF RENEWABLE

• Can a biogas refinery:• Take the excess of R.E. from the grid

and transfer it where is needed for a cost< 50€/MWh?

• Produce biofuel for a cost < than 50€/MWh and transport it in the gas grid?

• Is the gas grid the cheapest option (< 10€/MWh) for energy transport and storage?

CONCLUSIONS

• If we decarbonize overnight our energy system, would we be able to avoid the risk of abrupt climate change and stay < 1,5°C temperature increase? No…

• We need BECCS system, that are easy,scalable and cheap

• Biogasdoneright is a BECCS easy, scalable (>4 Gton C/year)

• Biogasdoneright contribute to increased photosynthesis, more food production, more renewable carbon production for energy and chemistry and storage of Carbon in the soil

• The biogas refinery is an effective tool to link the power with the gas grid , where the gas grid is the cheapest and effective way to store and deplace in the timespan and in the space large amount of energy

Example of Biogasdoneright in action: Cooperativa La Torre: 2 biogas plants of 1 MW each.Daily input: 90 tons cow manure, 90 tons cow slurries, 38 tons eggs laying chicken manure, 10 tons rabbit manure, 5 tons spent mushrooms litter, 10 tons sugar beets, 30 tons corn silage, 5 tons rye grass (all wet weights)Daily output (energy): 48MWh

CIBConsorzioItalianoBiogas e Gassificazione [email protected]: 09248721004

c/o Parco TecnologicoPadanoVia Einstein,Loc. CascinaCodazza Lodi(LO)

SegreteriaTelefono+39(0)3714662633 Fax +39(0)3714662401

Link

mailto:[email protected]

http://www.consorziobiogas.it/Content/public/attachments/527-Biogasdoneright%20No%20VEC%20-%20LowRes.pdf

OPERATIONAL PERFORMANCE – ENSURING PLANT STABILITY THROUGH DATA MODELLINGCHAIR: SONYA BEDFORD, STEPHEN SCOWN LLP

ANNA-KARIN, NYMAN, BUSINESS DEVELOPMENT EUROPE, ADVANCED BIOFUELS, DUPONT

DAVE AUNTY, BIOENERGY ENGINEERING MANAGER, CAPITA-PROJEN

URSULA KEPP, PROCESS ENGINEER, PATRICK NOLAN CONSULTING


NICK JOHNN, ENVIRONMENTAL CONSULTANT, AARDVARK

Using enzymes to drive profits and ensure plant stability

90

Anna-Karin Nyman, Business Development Manager July 6 - 2016

Agricultural wastes

Decentralized energy productionConsistent energy supplyLower cost feedstockReduced CO2 emissions/carbon footprintFarmland used for food crops rather than energy cropsAgricultural waste removalAdded value to wastes

91

Complex cellulosic biomass

Longer processing timesPre-treatments (mechanical or biochemical)Low yield/energy valueProcess instabilities (rafting, bridging)High DM or viscosity issues

92

Natures own pre-treatment

High residual fiber remaining in digestate /end productSubstrate adaption alone is insufficient Fungal organisms initiate the degradation process in natureEnzymes provide this pre-treatment

93

94

Cellulose degrading enzymes

Polysaccharide monooxygenasesMake cuts in crystalline cellulose chain

Cellobiohydrolase Break off small oligomers from cellulose chain

Endo-glucanases Cleave bonds in amorphous cellulose

b-glucosidaseBreak cellulose disaccharide into glucose

= crystalline cellulose= amorphous cellulose GH10 Endo-xylanases:

Less hindrance by side-groups (smaller oligosaccharides)GH11 Endo-xylanases: Hindered by side-groups (larger oligosaccharides)GH30 Xylobiohydrolase:Splitting off disaccharides GH3 β-Xylosidase:Splitting off xylose

Broad benefits observed

95

Increased biogas production (plant trial)

Increase methane/carbon dioxide ratio (plant trial)

Viscosity reduction (plant trial)

Increased fermentation rate (lab data)

Improved solubilization/fiber conversion (lab data)

Higher %TS operations

Greater feedstock flexibility

Improved process robustness

Agricultural co-digestion – Plant trial 1

1 MW biogas plant trial Farm substrate (cow slurry, corn silage and triticale)CSTR operating at 41˚C12% decrease in feedstock required to maintain biogas output

96


1200 kWh biogas plant trial Farm substrate (chicken muck, whey permeate, beet, corn)Plug-flow reactor operating at 39.5˚C; 35 day retention timeDecrease in substrate viscosity by 2-3x

97


2 MW biogas plant trial Farm substrate (pig/cow manure, corn, sugar beet, oat & sheatnut meal)Plug-flow reactor operating at 40-44˚C; 60 day retention time8% increase in methane production 10% decrease in operating costs

98

Product launch

DuPont’s first enzyme offering in a product pipeline designed specifically for anaerobic digestionTargets cellulosic, fibrous materials – agricultural residues, energy crops, paper productsImproves biogas yield and reduces risk of process irregularities, translating in cost savings for the biogas plant

DuPont Confidential | Copyright © 2016 DuPont. All rights

reserved.

99

OPTIMASH® AD-100

THANK YOU!

100

Operational performance modelling and optimisationAD & BiogasJuly 2016

Introductions

Dave AutyBioenergy Engineering

Manager

I’ve only got 10 minutes…

• What plant data do we need and why

• What do we need from the laboratories and why

• How to model the data

• Can we improve operational performance?

Plant data requirements (the essentials)

• Volume input to the digester, %DS and %VS• Hydraulic retention time• Organic loading rate

• Digester temperature, pH and digestate ammonium• Ammonia inhibition• C:N

• Digester gas volume and percent methane• BMP• Energy

Measure these 8 parameters every day and with a bit of knowledge you can fully

characterise the health and hence performance of your AD plant

Plant data requirements (the useful)

• FOS/TAC and alkalinity• Gives comfort to a ‘tramline’ model

• Digestate %DS and %VS• Enables BMP to be checked

• Hydrogen sulphide• Useful to know if inhibition is suspected

• Energy production• Enables gas production to be checked• It’s where the money is

We look for this data whilst troubleshooting a failing digester

Laboratory data requirements (once per month)

• Speciated VFAs• Acetogens vs methanogens• General biological health

• Micronutrients• Essential element quantities• Specific biological health

• Macronutrients and ptes• Digestate quality information for recycling purposes

These are used to keep an eye on the digester health and provide pointers if poor performance

is experienced

How to model this data

• Calculate absolute values of key parameters• HRT, OLR, BMP, NH3, Energy

• Compare to design/optimum values• Tramline model• Useful for overall performance level• Provides general biological health answers

• Calculate rates of change• Absolute key to optimisation in a slow system such as a digester• Provides rapid indication of biological health• Changes in mass balance provide key insight

There are many formulae and models that can be used. Provided they are based on sound

principles of chemical engineering, the model doesn’t matter. It’s what you do with the

model’s information that counts.

What to do with the information from the model

• Make it obvious where the data sits in the tramlines• HRT, OLR, BMP, NH3, Energy• Speedometers, bars, etc• Combine the key parameters into a single ‘Performance Score’

• Indicate the rate of change• Traffic lights, arrows, both• Provide contextual warnings of excessive rates of change• Provide graphics to indicate the key mass balances

Has to be useful information that is easy to assimilate by the person putting the data into

the model.

What to do with the information from the model (optimisation)

• This starts with good data management (GIGO)• Sense check the data at the input stage• Use surrogates and averages if data is not available

• IT makes it easy to drive the model• One click optimisation that is specific to the site and biological state

at the time• Provide the optimum condition information in the same way as the

day-to-day data for ease of comprehension• Predictions based on current performance – can be made to be

reliable if feedstock data is reliable

A good model can be driven to provide predictions and optimisations

Performance improvement is possible with a good model

• PROjEN are regularly called in to save failing AD plants• A pattern of plant failures has emerged• A pattern of operator errors has emerged• These failures were preventable

• We also know from Due Diligence projects…• Optimum performance is rarely achieved…• …but usually achievable

• So we created a service to prevent failures and improve performance

A good model must be based on sound principles, strong numerical analysis and ease of use

Uses a reliable model with strong numerical analysis as part of the service

The PROjEN AD Pilot+ Decision Support Tool

1

2 3

5

5

4

4

4

6

6

7

7

What does the PROjEN AD Pilot+ tool do? (normal operation)

What does the PROjEN AD Pilot+ tool do? (on a bad day at the digester)

What does the PROjEN AD Pilot+ tool do? (optimisation)

What does the PROjEN AD Pilot+ tool do? (prediction)

What is PROjEN AD Pilot+ ?- An AD Optimisation Service

• Simple basic data can be leveraged to provide good information

• Reliable modelling is easy with a little help from IT

• There is a need to improve the performance of existing digesters

• PROjEN AD Pilot+ can help by:

• Giving instant feedback on your digester’s performance

• Providing constructive knowledge and advice to the operator

• Providing a performance score

• Calculating what to do to optimise performance

• Predicting how the digester will perform

• Acting as an audited store of the essential performance data

• As an industry, we can improve performance by 30%

Summary

Thanks for listening

Contact:-Dave Auty – Bioenergy Engineering Manager

E-Mail: [email protected] Line: 01928 752 596

Mobile: 07961 560 104

OPERATIONAL PERFORMANCE – ENSURING PLANT STABILITY THROUGH DATA

MODELLING

UK AD & BIOGAS 2016

URSULA KEPP

Continuous process supervision

Visual supervisionOnline available data (SCADA)Sampling and laboratory results

Visual supervisionInformation about mixing conditions at

surfaceSulphur depositsFormation of floating layersFormation of foamViscosity

Potential problems prevented by visual supervisionEarly increase of mixing to bring floating

material back into main digester content, reduced risk of process acidification

Foam formation as indicator of suboptimal conditionsIrregular feeding scheduleHigh fat content in recent feedMixing problems causing uncontrolled

intermediate high gas formationExcessive feed of easily degradable materialInsufficient availability of trace elements

Data available from the SCADA systemAvailability and power uptake of equipmentControl of current operation

Feed tonnage, tank levels, liquid transfer flows, gas flows, gas quality separate for each tank, temperature at several points, filling level of gas holder

Used in plant optimisation for:Short term for direct supervision of technical

performanceLong term by use of trends for general process

efficiency and problems developing over time

Trend for power uptake of mixers

Problems with gas engine resulting in efficient use of feedstock

Sampling and laboratory analysisSample has to be from a representative point,

preferably from a pipe Parameters directly used in operational

decisions should be analysed on site: pH, FOS/TAC, gas quality

Typical laboratory analysis: dry matter, VFA, ammonium

Sampling frequency depending on feedstock (energy crops, food waste) and changes in feedstock (food waste from different sources)

Minimum sampling requirementsAbsolute supervision minimum is gas quality

and pHSupplemented by weekly/twice monthly

sampling of dm and FOS/TACFOS/TAC is not suitable in the early stages of

commissioning when fermenters are filled with water rich seed material, lacking alkalinity

VFA have to be considered in combination with pH as bacteria and methanogens can only utilize unionised VFA.

FOS and VFA do not correlate well

Alternative method developed in 2001 for Cambi (Norway)

Operational PerformanceEnsuring plant stability through data modelling

Presenter – Nick Johnn

Introduction

Due DiligenceOperational Troubleshooting

Sustainability Criteria

Case Studies

Why record performance data?

Operational Performance

Demonstrating competence

Feedstock trials

Aardvark AD Benchmarking

Aardvark AD Benchmarking Forum

• Sharing Insights & best practice• Feedstock choices• Emerging technologies• Revenue streams and uses for heat

Importance of Operational Data

• Performance purposes, diagnostics

• Also touch on sustainability requirements, record keeping etc.

• Supply contracts

• Investor confidence

• EMS/MMS requirements

• Learning

OPERATIONAL PERFORMANCE – WHY ISN’T MY PLANT RUNNING AT 100%CHAIR: ALEXANDER HENDERSON, ORA

DR EMMA BRODRICK, SYSTEMS APPLICATION MANAGER, IMSPEX DIAGNOSTICS

TONY CLUTTEN, PROCESS SALES MANAGER, HUBER TECHNOLOGY

PHIL HOBBS, DIRECTOR, NEW GENERATION BIOGAS

FOLLOWED BY OPEN DISCUSSIONNORBERT ROSSOW, EPRV/FARMGAS COMMUNITY PARTNERS LTD

DR MELANIE HECHT, BIOGAS PROCESS MANAGER, SCHAUMANN BIOENERGY

Operational performance

Why isn’t my plant running at 100%?

Alexander Henderson6th July 2016

www.o-r-a.co.uk

What is 100% of?• Technology provider’s estimate?• Design expectation?• Investor’s expectation?• Published literature or other plants?• Potential in terms of other on site assets?

Dr Melanie Hecht, Biogas Process Manager, Schaumann BioEnergy

Key problems for stable digester performance

Dr. agr. Melanie Hecht

UK AD & Biogas 2016, Birmingham, 6th July 2016

In the UK and Ireland, we are working in partnership with

143

144

Job Description

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%0

1000

2000

3000

4000

5000

6000

What‘s there to lose?

Degree of downtime [%]

Loss

es p

er d

ay [£

]

249kW / 9.12p/kWh

500kW / 8.42p/kWh

1,000kW / 8.68p/kWh

2,000kW / 8.68p/kWh

3,000kW / 8.68p/kWh

145

Common process disruptions

AcidificationOver-feeding

InhibitionTemperature change

Trace element deficiency

Low gas yieldsLow feedstock qualityNutrient deficiencies

InhibitionInadequate mixing

High ViscosityFoaming

Hydrolysis disruption

OthersFoaming

Gas QualityMechanical Faults

Floating LayersSedimentationDead Zones

146

Zn

Mo

Mn

Ni

Co Se

Micronutrient Deficiency

Health & Safety

148

High Viscosity

Low Viscosity High Viscosity

Flow velocity [m/s]

Can your stirrer meet the challenge?

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Dead Zones, Sedimentation, Floating Layers

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100

80

60

40

20

HRT (days)

sugars, fatty acids, amino acids

starch, proteins, pectins

hemicellulose, cellulose

Plan

t Com

pone

nts

(%)

lignins, waxes, resins

Digestion Speed

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Plan

t Com

pone

nts

(%)

100

80

60

40

20

HRT (days)

with enzymes: increase of speed

sugars, fatty acids, amino acids

starch, proteins, pectins

hemicellulose, cellulose

… with Enzymes

154

Dr. agr. Melanie Hecht Schaumann BioEnergy GmbH

An der Mühlenau 4D-25421 Pinneberg

phone: +49 (0) 4101 / [email protected]

www.schaumann-bioenergy.eu

Thank youPlease come and see us at the stand J303

156

Operational performance - why isn’t my plant running at 100%?

Dr Emma BrodrickSystems Application [email protected]

UK AD & Biogas 2016Venue: Hall 3 – NECTheatre: Green SeminarTime: 14:00 – 14:55, 6th July 2016

Siloxane Monitoring using

GC-IMS

158

Overview

Company:IMSPEX/GAS UK and GermanyManufactures of GC-IMS devices

Case study 1:Siloxanes profiling of a landfill site

Continuous monitoring of an anaerobic digester plant

Technology:Gas Chromatography - Ion Mobility SpectrometryGC-IMS-Silox monitors siloxanes concentrations in biogas

Case study 2:

159

The siloxane problem

Siloxane Hexamethyldisiloxane L2Octamethyltrisiloxane L3Decamethyltetrasiloxane L4Dodecamethylpentasiloxane L5Hexamethylcyclotrisilixane D3Octamethylcyclotetrasiloxane D4Decamethtylcyclopentasiloxane D5Dodecamethylcyclohexasiloxane D6

Where does it come from?Washing agents, cosmetics, skin care products, waterproofing materials, shoe polish

160

The siloxane solution

o On-line and continuous monitoring of siloxanes

o Very low detection limits down to (μg/m3)

o Portable on-site operation

o High reproducibility and accuracy

o Very low running and maintenance costs

161

At site on line monitoring of siloxanes

162

Case study 1: Siloxanes profiling of a landfill site

o Siloxane monitoring on an active site landfillo Partially cappedo Gas to flare and site self sufficiencyo Engine break down +10%o No filter systemo Unknown concentration of siloxane

163

Case study 1: Landfill schematic and sampling points

63

5a

1

2

45

Engine or

Flare

Bore holeManifold sampling point

164

Case study 1: Siloxane results at multiple manifolds

Location Name TOTAL Si TOTAL SiO2 TOTAL

SILOXANES L2 L3 L4 D3 D4

Blank (pure nitrogen) 0.02 0.03 0.05 0.00 0.02 0.00 0.03 0.00

Flare 1.00 2.01 2.82 0.19 2.48 0.01 0.12 0.02

Manifold 1 0.89 1.78 2.49 0.15 2.16 0.02 0.16 0.01

Manifold 2 0.50 1.00 1.41 0.12 1.23 0.02 0.04 0.01

Manifold 3 0.66 1.33 1.87 0.18 1.60 0.00 0.07 0.01

Manifold 4 0.76 1.52 2.14 0.21 1.80 0.01 0.11 0.01

Manifold 5 1.47 2.94 4.13 0.33 3.64 0.01 0.13 0.03

Manifold 5a 1.67 3.34 4.68 0.20 4.21 0.02 0.21 0.03

All results in mg/m3

165

Case study 1: Next steps…

Flare

High volume through filter

Reduced filter life

166

Case study 1: Next steps…

Flare

167

Case study 2: Continuous monitoring of an anaerobic digester plant

o AD from food waste o 5 digesters on siteo Gas turbines with electricity sold to grido Long down time related to engine faultso Unknown source of problemo Suspected siloxane issue

168

Case study 2: Schematic and sampling points

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Conc

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(m

g/m

3)

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Case study 2: GC-IMS sampling results = Filter change

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Lab Total Siloxanes (mg/m3) Lab Organic Silicon (mg/m3) GC-IMS Total Siloxanes (mg/m3)GC-IMS Organic Silicon (mg/m3) Engine spec Organic Silicon (mg/m3)

Conc

entr

ation

(m

g/m

3)

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Case study 2: GC-IMS v Lab results = Filter change

Case study 2: Identifying the source

173

Margarine…

o Food waste from commercial and industrial sources

o Tested siloxane concertation from the output of each digester

o Traced deliveries from food sources

o Large batches of margarine from local producer

o On-line and continuous monitoring of siloxanes

o Very low detection limits down to (μg/m3)

o Portable on-site operation

o High reproducibility and accuracy

o Very low running and maintenance costs

Review: GC-IMS for online siloxane monitoring

174

Thank You

175

Contact:Dr Emma BrodrickIMSPEXUK

Email: emma@imspexTel: 01443 740217

HUBER TECHNOLOGY . www.huber.co.uk

ADBA Why isn’t my plant running at 100% 6th July 14.00-14.55

ORGANICS v CONTAMINANTS-WHAT DO YOUR BUGS WANT

MSW wasteFood and Vegetable BiomassKerbside and supermarket

Inorganics such as Glass, sand, metals, heavy plastics and grit together with unwanted Organics like eggshells, and sea shellsare not digestible

http://www.huber.co.uk/



Huber Expertise

Huber are Liquid / Solid Separation Engineers and have been able to apply that knowledge to some of the challenges to improve the performance of Anaerobic Digestion:

Removal of Grit and glass Coarse Screening to remove oversize Removal of floating debris Polystyrene Removal of plastics Washing plastics for Organic recovery

PHYSICAL REMOVAL OF CONTAMINANTS IS OUR BUSINESS, SO WE ACCEPT THE CHALLENGE.




THE QUALITY AND QUANTITY OF PLASTICS REJECTS DEPENDS ON THE DE-PACKAGING PROCESS AND FEEDSTOCK. WE HAVE

FIGURES VARYING FROM 7 TO 22% FROM SOURCE SEGREGATED AND SUPERMARKET WASTE.

LETS GET THE ORGANICS BACK IN THE SOUP

RECOVER ORGANICS FROM REJECTS

TIGER DEPACKAGING-TRIAL WASHPRESS UNDER DISCHARGE

TIGER REJECT 7.5% WASHED AND DEWATERED ORGANICS RETURNED OF FEED SCREENINGS TO SOUP 40-60% REDUCTION




REJECT WASHING TO GET ORGANICS

WASHPRESS ON BTA PULPER TRIALS IN BELGIUM

AND SPAIN

REJECT TO LANDFILL OR RDF ORGANICS RETURNED TO SOUP




Built in 1999 in Boden Germany Huber were tasked with removing the oversize from a 12%DS soup from a Pulper (Monsal type) after Pasteurisation. Plant takes Green and food waste.The screen is followed by a grit trap removing 12TPD.

The design warrants heavy duty construction and drives and after 14 years the unit is operating well removing oversize from the soup at ~60 C ̊

Oversize removal from soup


SCREENINGS WASHING-Swedish Plant

Wash Press in Sweden working on screenings from a Huber screen after a Hammer Mill.

Screenings before washing

Screenings after washing

The weight deduction to Landfill is 10-14% but this depends on the upstream process. Return organics means increased gas yield and less landfill.

BY WASHING AND DEWATERING YOUR SCREENINGS ORGANICS CAN BE RETURNED TO THE SOUP



INEFFICIENCY DUE TO GRIT AND GLASS

Grit and Glass are a major problem to AD Operators1. Causing pump and pipe wear 2. blockages 3. Parasitic load increase due to mixing

and pumping power increases. 4. But the other hidden enemy is

sedimentation in the stock tank and digester. If your Digester is say 30% full of grit then that’s 30% less retention time with subsequent gas losses, heating costs etc.

Grit and glass and heavy plastic can be settled out on a Huber longitudinal grit trap

Settled soup containing grit and glass and plastics


HUBER TECHNOLOGY . www.huber.UKNovember 2010

LONGTITUDINAL GRIT TRAP TO REMOVE HEAVY FACTION

12.5% DS Food Waste Soup Ro5 Bio 50 in UK

Trapezoidal channel Grit and glass removed



REMOVAL OF INDIGESTABLE GRITTrials in Boden and on the Shanks grit trap have looked at separating the organics from the settled grit

Trial Grit washer at Shanks

Recovered organics ~40% Cleaned grit, bone, eggshell, less tolandfill sea shell




BLACK BAG WASTE- MSWTHE GRIT AND GLASS IN UNSEGREGATED BLACK BAG WASTE IS

EXCESSIVE AND WARRANTS ANOTHER STEP UP IN DESIGN EFFICIENT CONTAMINANT REMOVAL IMPROVES AD PLANT

EFFICIENCY

Light fraction screen at Bredbury Parkway

Heavy fraction classifier under a BTA pulper.Note dump valve feed.


Tel.: 01249 765050eMail: [email protected]

Thank you very much for

your attention


http://www.huber.c/

Phil Hobbs

Introduction- integrated approach Why is start-up important?

Legal contracts and AD plants

Inoculating- principals

Monitoring

Operating problems

Failed and successful digester compared

Process control

Feedstock balance C:N

Inoculum sources

Maintenance

Analytical monitoring

Management

Plant design

Why is start-up important?

• Start up of an AD plant is critical to its long term performance

• Inoculation is a critical process with up to 20% effect on biogas yield and plant output

• Could mean losses of

• 250kW plant £63,000 pa

• 1MW plant £230,000 pa

• Increased feedstock demand and difficulties for the digestate to meet the PAS 110 standard

Feedstock directs dominant methanogenTypes of waste Dominant methanogens

Brewery wastewater Methanosaeta concilii

Palm oil mill effluent Methanosaeta concilii

Dairy waste Methanosarcinaceae, MethanobacteriumThermoautotrophicum

Cheese whey anddairy wastewater

Methanococcus spp.Methanosaeta spp.

Pulp and paperwastewaters

Methanosarcina sp.(Methanosarcina barkeri)

Olive oil millwastewaters

Methanosaeta sp.(Methanosaeta concilii) Methanobacteriaceae(Methanobacterium formicicum)

Principals of inoculation Microbial population is critical to

Good biogas production Robust digester performance

Introduce the best sources of inoculum from effective digesters

The source of inoculum not only affects the amount of biogas production but also the kinetics rate of the process

Principals II Diversity is established at “start

up” Seeding will introduce

diversity

Establishing the right community at the start is key

Post start up the community will only change if Increased death rate prior to

inoculation Strong selective pressure

Actual Diversity Full Scale 1018 Bacteria- 2698

species Bench Scale 1012 Bacteria 475

species

Source Prof Tom Curtis

Primary stage Inoculation Optimal approaches - hot sourcing

digestate from a similar plant running similar feedstocks

Important to use multiple sources to prove a range of inoculating possibilities

Balance inoculum with feedstock VS:VS ratio of 1

Start-up - a part of the equipment supply contract?

Physical environment Mixing should be slow to help new

and interacting communities develop

Add water to minimise headspace volume

Ensure the temperature is + 1oC as methanogens are temperature sensitive when producing methane

Dry matter below 8% w/v at start (kinetics and mixing influence)

Biochemical environment Daily testing and recording

WHY - Feedstock – rubbish in……..

pH between 6.7 and 7.4 for single vessel C:N ratio of between 15 and 30 Phosphorus should be ca 1% of the COD Ensure ratio of VFAs to alkalinity is between .1 and .3 Minimum concentration of trace elements

Digester healthVFA/ALKALINITY RATIO COMMENT ACTION

>0.6 Highly excessive feedstock input Stop adding feedstock

0.5 – 0.6 Excessive feedstock input Add less feedstock

0.4 - 0.5 Plant is heavily loaded Monitor plant closely, adjust feed

0.3 – 0.4 Optimal biogas production Monitor, maintain feed rate

0.2 – 0.3 Feed rate too low Slowly increase feed rate

>0.2 Feed rate far too low Increase feed rate

Evolving feed rate• Representative and timely sampling

• Determine relevant parameters DM, VS

• Assess biogas output and methane content

• Determine FOS/TAC ratio

• Increase feedstock rate by 0.X kg/m3 if FOS/TAC ratio is <0.15 and methane percentage is increasing

Example - failed start-up

Summary • Detailed planning of the start up phase, covering inocula

loading, feeding and testing• The acquisition and use of an efficient inocula from different

sources or a fully operating digester• Provide the correct physical and biochemical environment to

initiate biogas production• Recognition of when to add feedstock by timely and

appropriate monitoring of the anaerobic fermentation• Application of the fermentation parameters to gradually

increase the feeding rate

Improving the efficiency of biomethane production – PRV pretreatment system Kombi-Hydrolysis with Wave-

BoxADBA: UK AD & Biogas 2016; Birmingham, July 6th 2016

Norbert RossowManaging Director

PRVPlanungsbüro Rossow

Gesellschaft für Versorgungstechnik mbHLindenhof 2c

D - 17033 Neubrandenburg

Phone: +49 395 7074709Fax: +49 395 7782138

E-mail: [email protected]: www.rossow.de

PRV Who we are

> Qualified and specialized staff (biologists and engineers of various disciplines)> Planning of heating, cooling and air conditioning systems> District heating systems> Production and energetically utilization of biogas> Improvement of biogas production efficiency> Research and development projects> 20 year experience in engineering of biogas plants> More than 100 plants realized> Pioneer in biogas technology> First farm-scale plant in North-East of Germany> First biogas plant in North-East of Germany> Advanced technologies for manure biogas production

ADBA: UK AD & Biogas 2016; Birmingham, July 6th 2016, Norbert Rossow, Planungsbüro Rossow Gesellschaft für Versorgungstechnik mbH

Examples of research products and patents

Ultrasound Wave-Box

PRV

PRV – Kombi Hydrolysis

High Performance Digester

Express Hydrolysis


PRV

New patented system “Multi E” for efficient biogas production from manure and agriculture residues


Kombi-Hydrolysis Blumberg Efficient biogas production from pig manure and organic waste

PRV


Potzlow Biogas Plant (North-East Germany) with Kombi Hydrolysis

Feed: manure and dairy slurry

PRV


Ultrasound Biomass Treatment Ultrasound technology enhancing biomass degradation

Cavitation effects of high power ultrasound:- Destruction of volatile solids- Enhancing of biogas production- Reducing of sludge and digestate


5

Light-microscopical Analysis

untreated WAS 30s sonicated 90s sonicated

energy energy


6

Effect of sonication on particle size distribution

0%

25%

50%

75%

100%

1 10 100 1000Particle size [µm]

Volu

me

cum

ulat

ive

[%]

Reference

30 W/L, 20s (= 0.17 Wh/L)

80 W/L, 20s (= 0.44 Wh/L)

220 W/L, 20s (= 1.28 Wh/L)

310 W/L, 20s (= 1.72 Wh/L)


PRV

PRV-Pre-Treatment-SystemKombi-Hydrolysis with Wave-Box

Problem Solution Results • Clogging by fibers No blocking• High viscosity Less viscosity• High agitating effort Less agitating/pumping• Low CH4-content Higher CH4-content• Few biogas More biogas• Wear and tear of No feeding device

feeding device necessary


PRV

Pre-Treatment-SystemKombi-Hydrolysis with Wave-Box

• Applicable with: - mono-digester - high-efficiency-digester - Multi-E-system - most existing biogas plants

• More stability in biological process, because of - multi-cycling of substrates between Kombi-Hydrolysis and digester

• High rate of disintegration, because of stepwise process by - multi-cycling of substrates between digestate, Wave-Box and Kombi-Hydrolysis


PRV

Pre-Treatment-SystemKombi-Hydrolysis with Wave-Box

• Increasing efficiency: - less remaining organics - different kind of substrates - methane yield up to 30% higher

• Low investment costs - replaces worn mechanical feeder - use of existing (hydrolysis) tanks

• Less maintenance: - no tear and wear of mechanical feeder - better viscosity of medium - less load for agitators and pumps


Ultrasound Biomass Treatment Ultrasound technology enhancing biomethane production

Results of Ultrasound installation (Wave-Box)at biogas plant Cammin:–15% reduction of maize feeding– 7% higher biomethane concentration–50% reduction of viscosity


Comparison of fresh organic matter and remaining organic after digesion with different pretreatment process


Synergistic effects of Kombi-Hydrolysis and Wave-Box

• Increasing efficiency: - less remaining organics - methane yield up to 30% higher

PRV - Biogas plant 1,1 MW in Turkey Layout and key figures for manure biogas plant

Input:78,000 t/a cattle slurry5,000 t/a greenhouse waste3,000 t/a maize silage

AD-process:- Pre-treatment system: Wave-Box & Kombi-Hydrolysis- Digester 6,000 m³ net volume

Yield:approx. 4 Mill. m3/a biogas

Electrical energy:approx. 9.5 Mill. kWh/a

Availability: 8,400 h/a


Renewable energy village with biogas plant, district heating and power generation by CHP; photovoltaic system

PRV


PRV Our experience – your benefit!

Thank you for your attention

Planungsbüro Rossow Gesellschaft für Versorgungstechnik mbHLindenhof 2cD - 17033 NeubrandenburgPhone: +49 395 7074709Fax: +49 395 7782138E-mail: [email protected]: www.rossow.de


Farmgas Community Partners Ltd.IMI Business ParkSandyford Road • Dublin 18Ireland

Phone: +353 (0) 1 901 2622E-mail.: [email protected]: www.farmgas.ie

ON-SITE AD – WHICH INDUSTRIES & SECTORS NEED TO PRIORITISE ON-SITE DEPLOYMENT

CHAIR: RICHARD GUETERBOCK, CLEARFLEAU

MARTIN RIGLEY MBE, MANAGING DIRECTOR, LINDHURST ENGINEERING

NICK JOHNN, ENVIRONMENTAL CONSULTANT, AARDVARK


RYLAND CAIRNS, ENVIRONMENT MANAGER, MUNTONS

WILL LLEWELLYN, DIRECTOR, RED KITE MANAGEMENT

Chair: Richard Gueterbock, Clearfleau

Anaerobic DigestionTowards a Circular Economy: Case StudyRyland Cairns

Plant & Performance

Why we opted for Anaerobic Digestion

Setting the Scene

Overview

Realising Benefits & creating a circular economy

Research and Innovation Commitment

Values: Sustainability

Malt Ingredients

Malt

Who are Muntons?

ENERGY USE PER TONNE WATER USAGE

WASTE & RECYCLING

27% LESS

14% LESS

0% to LANDFILL

6% below target

We like to lead by example

Considering all areas of the supply chain: from farm to consumer

Carbon footprint

COD

2,000 mg/l

COD

30,000 mg/l

Tankers

AEROBIC PLANT to River

Why Anaerobic Digestion?

Anaerobic Digestion

Feed in Tariff (FIT) & other

incentives will be phased out:

timeline unknown early action required

Previous AD plant not operational

Factory reliant on timely sludge

disposal>80,000 tonnes p.a. Effluent tankered

off site

Costs likely to rise substantially

Increased environmental

scrutiny and regulation

Why did we need it now?

Total project Cost: £5.5MPlant Life >25 yrs

Sale of Bio-Fertiliser to local farmers

Reduced electricity cost: up to 10-15% at half priceIncome from Government Feed-in-Tariffs

Off-site Tankering costs £732,000

£650,000

PAYBACK 4.6 years

A nice little earner!

CHP PlantUASB DigesterEnprotech

MI Effluent CHP PlantEnerG

DAFAerobic

Treatment Plant

RiverMalt

Effluent

Basic Process Flow

Sludge TreatmentHRS & GEA

Bio Fertiliser

Parameter Figure

Flow 200m3/d

Total COD 30,000mg/d

HRT 10d

OLR 3.1Kg/COD/d

Vup 0.04m/d

COD/SO4 Ratio 65

Total COD Removal 80-90%

BMP 30-50 mgCH4/mgCOD/d

Plant Performance

Biogas Component % contribution

Methane 65

Carbon Dioxide 33

Hydrogen 1.0

Nitrogen 0.6

Oxygen 0.1

Hydrogen Sulphide 0.1

Biogas Analysis

Bio-fertilizer Parameter Figure

Dry Matter 25% m/m

Loss on Ignition 69% m/m

Total Nitrogen 65% m/m

Total Phosphorus 2.8% m/m

Total Sulphur 2.1% m/m

Daily Production 4-5T day

Biofertilizer Analysis

Generates ~1800t of high quality bio-fertiliser p.a. for use on Malting Barley land

Heat from engine will heat the MERF as well as pasteurise the fertiliser

The new AD plant is operating 40% under capacity.

225,000km less road haulage

p.a.

350-400 tonnes less CO2

emissions p.a.

Future Sustainability

BARLEY

MALTBIO-FERTILISER

MALT INGREDIENTS

Creating a Circular Economy

Reported to us by funders:

1/3rd of plants do not work1/3rd of plants work partly1/3rd of plants work as designed

Many funders didn’t understand the technology

Some who understood the technology want too much for the privilege of funding

Thank you to our supporters

So good that nobody wanted to fund it – WHY?

Technical Understanding of AD for operators

Technical Understand of AD for regulators

Improved RegulationsBarriers to Entry

Improving Confidence

RaisingIndustry

Standards

http://adbioresources.org/

Biofertiliser Composition

Muntons: Committed to R&I

Biofertilizer Efficacy

Reducing H2S in a AD biogas

• £5.4m investment

• Local field to factory cycle

• Payback <4.5 years

• Reduced CO2 emissions from 27,264 tonnes to 26,605 tonnes

• 3000 less tanker movements (225,000km)

• Generates ~12% site electricity demand

• Produce quality organic fertiliser

Anaerobic DigestionTowards a circular economy

Will Llewellyn ADBA 2016

Vehicle Fuel Using biomethane from food processing residues Will Llewellyn

Director, Red Kite Management Ltd.


Methane: A clean fuel

Current HGV fleet: 340 Dual Fuel – Mostly LNG 168 Dedicated LNG / CNG inc.

buses


Biomethane / CNG supply chain


Filling stations: Current UK deployment Supply chain

Energy densityStorage


OEM dedicated gas vehicles


Dedicated CNG HGV: Scania Euro 6


Dual fuel HGV: Retrofit


Integration with on site AD plant

Feedstock Biogas

CHP

Heat for AD

Electricity for AD

Vehicle Fuel

ADBiogas Upgrade

Electricity for Up-Grade

Electricity for Export


Summary

• Biomethane a clean fuel – Low NOx, no particulates• Upgrade an ideal solution where AD plant is

restricted by grid capacity or feed in tariff banding• Can take gas out of grid after RHI• Green Gas certificates to guarantee biomethane /

origin• OEM vehicles available: CNG technology has built a

“bridge” to biomethane as a vehicle fuel.• Lower carbon footprint than petrol or diesel• A truly sustainable, low carbon fuel.


Thank you

[email protected]

On-Site ADWhich industries and sectors need to prioritise on-site deployment

Presenter – Nick Johnn

Introduction

Due Diligence

Operational Troubleshooting

Sustainability Criteria

CO₂ Capture from AD

CO₂ Capture from AD – How does it work?

Benefits of CO₂ Capture• Retrofit options

• No DECC subsidy links– Newness criteria– Degression

• Source of additional revenues

• Cost saving opportunities

• Reduces Carbon Footprint – Sustainability Criteria

• Improves the carbon cost-effectiveness of the AD sector

• Good range of markets– Horticultural – Fire extinguisher– Welding gas– Dry ice– Food & Beverage– Refrigeration

Challenges / Considerations of CO₂ Capture

• Capital Investment & Plant size

• Feedstock options/restrictions – end of waste issue / QP for gas production

• Planning issues – increased vehicle movements

• EIGA Spec compliance

Martin Rigley MBE, Lindhurt Engineering

H2ADH2AD, income & energy from waste at source for a sustainable energy future

Darren Bacon & Martin Rigley MBE

Market potential

*AD shared goals, 2009

The UK produces over 100 million tonnes of organic material per year, which could be used to produce biogas*, this approximately breaks down as:

o Approx. 8 million tonnes of food wasteo Approx. 2 million tonnes of sewage sludgeo Approx. 90 million tonnes of agriculture material

Less than 1% of the 100 Mt is currently treated by AD

The technology applied to a farm

o Cow slurryo Waste milko Waste Effluents

o Biogaso Bio - fertiliser

H2AD technology is a hybrid form of traditional Anaerobic Digestion (AD) & Microbial Fuel Cell (MFC) technology cleaning up waste effluent using “the power of microbes” simultaneously producing bioenergy in form of biogas & fertiliser

OUT

ANOD

E

CATH

ODE

IN

Bacteria

CO2 H2 CH4e- e-

CO2H2

H+

CH4

Advantages of H2ADo Fast rate novel AD system utilising

Microbial Fuel Cell technologyo Green energy recovery from wasteo Tremendous impact on reducing

CO2 emissionso Small footprinto Modular and scalable o Odour controlo Low maintenance costso Remote monitoringo Attractive return on CAPEX

Differentiation from traditional AD

H2ADAD AD H2AD AD H2AD

Chemical Oxygen Demand reduction (%)

Hydraulic Retention Time (days) Energy Input (˚C)

Pay back (average years)

AD H2AD

Footprint (m3per ton of slurry)

Plant build and commissioning (months)

AD H2ADAD H2AD

Pilot Plant

Results to date o H2AD operating on a farm over

18 months

o 1 to 3 days retention time

o Reduction of COD, N, P, K in the liquid (50% reduction)

o Polishing step after the MFC to further optimise the process developed & tested achieving further 90% of COD removal

o Above 1:3 conversion ratio feedstock to biogas without crops

o 10,700 l of biogas per day (72% CH4)

A scalable system with a low cost entry point

Back end

Front end

H2AD 120

PLANT

PLANT

H2AD 30 H2AD 60

Effluent pre-treatment

Output separation & utilisation

PLANT

H2AD 180

PLANT

Prevention

Reuse Waste

Recycle

RecoverDisposal

Reuse Waste

Recycle Waste

Recover Energy From Waste

Disposal

H2AD Waste Treatment

H2AD Energy Production

Climate Change Impact

H2AD provides a solution for the middle three elements of the Waste Hierarchy

* The new European Waste Framework Directive (2008/98/EC): Prevention, prepare for reuse, recycle, recover other value (e.g. energy), disposal

Climate Change Impact

3.5 l/hr slurry

1 cow

75% of the carbon footprint to produce milk happens on farm, by using H2AD we can offset the

carbon at source

2,575 tonnes of usable slurry/y

1,800 tonnes of CO2 savings/y

120 cows

OUTIN

Bacteria

CO2 CH4 H2e- e-

CO2H 2

H +

CH4

2,000 farms = 3.5 Mt of GHGs saved

Target sectors

o Food & Drink Manufacturers – Soft drinks – Foods – Brewing

o Industrial residues– Bio-fuels – Bio-manufacture – Pharmaceuticals – Medical

o Agriculture/Farms – Waste Milk and/or Slurry

o Dairy Processing – effluents from milk processing

o Waste industry– Waste water treatment– Anaerobic digestion (AD)

leachate (polishing)

H2AD Awardso Shell Springboard Awards for Big ideas on

Climate Change runner up

o KTP Certificate of Excellence

o KTP Best of the Best Award - Finalist & Engineering Excellence runner up

o Food & Drink Inet Innovation Award - Development of ground-breaking technology to turn waste into renewable energy

o Food & Drink Inet Innovation Award - Most Innovative Positive Impact category

o Horizon 2020 Seal of Excellence

Horizon 2020 – Demonstration Siteso Spain – Ainia Centro Tecnologica – Technology Centre focused on the agro-food

sector & related industries (over 900 food manufacturers members) experience in energy efficiency, carbon footprint & ACV assessment, cleaner techniques & renewable energy - http://innovation.ainia.es/priority-know.html

o Southern Ireland – Irish Bioenergy Association - Represent the Irish Bioenergy industry to increase understanding of biomass supply chains to generate energy in the form of heat, electricity & motion. AD is core area for the association. IrBEA has a dedicated AD Subgroup & has commercial links to over 200 partners in the agri-food & drink processing industry - http://www.irbea.ie/

o Denmark - Aarhus University School of Engineering - technical Centre of Excellence for AD, with further links to other industrial bodies, such as the technology section of the Nordic Association of Agricultural Scientists & collaborations within academic networks - http://ase.au.dk/en/

o England - Castle Rock Brewery, Nottingham & Oakfields Farm, Derbyshire-Mixed waste/farm holding

Questions & discussion

HOW TO CAPTURE AND USE HEAT FROM AD EFFECTIVELY

CHAIR: GARY COLLINS, AB

MARCO CORNAGLIA, EISEMANN ITALIA

DR BARNEY MCMANIGAL, POLICY MANAGER, THE ASSOCIATION FOR DECENTRALISED ENERGY


ARNOLD KLEIJN, PRODUCT DEVELOPMENT MANAGER, HRS HEAT EXCHANGERS

STEFANO GANAASIN, PRODUCT SPECIALIST, TRIOGEN

STEVE RICHMOND, HEAD OF MARKETING AND TECHNICAL SOLUTIONS, REHAU

CASE STUDY FROM AB: A CLOSED LOOP FROM FOOD WASTE TO ENERGY THANKS TO ECOMAX® CHP

SOLUTION

AB IS THE GLOBAL LEADER IN COGENERATION. WE ENGINEER, MANUFACTURE, INSTALL AND MAINTAINTOP QUALITY CHP SOLUTIONS.

ABOUT USWHO WE ARE

276

ABOUT USINTERNATIONAL BRANCHES

277

ABOUT USOUR PEOPLE

278

ABOUT USFACTS & FIGURES

279

ABOUT USFACTS & FIGURES

280

PRODUCTION FACILITYThe largest area worldwide entirely dedicated to the industrial production of cogeneration systems.

ABOUT USINDUSTRIAL HUB ORZINUOVI

281

WEB CHANNELBIOGAS CHANNEL

VISITS FROM 50 COUNTRIES,5 CONTINENTS

MORE THAN 750 VIDEOS ON BOARD

16 TOPICS

282

http://www.biogaschannel.com/en

CHP IS STRATEGIC FOR THE FOOD SECTOR

284

AMADORI

AMADORI is one of the main industrial companies in the poultry sector in Italy

The Company has always beencommitted to eco-sustainability,aiming at finding a balance between reduction of the consumption and the increase of energy efficiency.

285

THE ENERGY HUB ATAMADORI’S CESENA SITE

286

ECOMAX 6 BIO

Power biogas

Feedstocks Fats, proteins and breadcrumbs waste

Biogas flow rate 313 Nm3/h

Electric power produced 625 kWe

Total electrical efficiency 40 %

Thermal power produced:from engine cooling waterfrom exhaust gas fumes

kW 381kW381

287

ENERGY EFFICIENCY FOR AMADORI’S TERAMO SITE

ECOMAX 11 BIO

Power biogas

Feedstocks Waste from the slaughtering process

Biogas flow rate 540 Nm3/h

Electric power produced 999 kWe

Thermal power produced:from engine cooling waterfrom exhaust gas fumes

kW 578KW 74

288

ECOMAX 11 BIO

BIOGAS COGENERATION IN THE CESENA ENERGY HUB

289

Watch the Biogas Channel video

https://www.youtube.com/watch?v=JAJKAaAzq6Q&list=PL6YXN7XHuc7Z5B6t_TRd9ZsfFzGUTgh-G&index=10

Ecomax® 11 BIO

Lay-outEcomax® 9-14 BIO – EGHE with bypass, on the roofLength depending on the Ecomax Module Width 3 m for the Ecomax® 9 -14 BIO

Flow diagramECO 10 BIO, hot water EGHE with bypass

ON/OFF 3-way valveExhaust bypass

Dry cooler capacity equals engine cooling thermal

power

Ecomax® BIO

SAFETY BIOGAS FLARE

BIOGAS TREATMENT SYSTEM

AUTOMATIC LUBE OIL REFILLING SYSTEM

HOUSING CONTAINERS FOR ENGINE AND AUXILIARY DEVICES

PLATE-TYPE HEATEXCHANGER

MONITORING SYSTEM

AIR INLET SYSTEM

EMERGENCY DRY AIR COOLERS

SILENCER AND EXHAUST STACK

THANK YOU FOR YOUR ATTENTION!

294

For more information:[email protected] Energy UK LTD


UK AD & Biogas 2016

How To Capture And Use Heat From AD Effectively

AD Plant Case Study

Digester

MechanicalSeparation

CHPPretreatment

Feedstock

Compost Liquid digestate

Biogas

Heat

CHP @ 100% capacity: Electrical output: 1000 kWHeat output: 1147 kW

Feed:47,500 t/year = 130 t/dayIncluding food waste: 51 t/day

Total digestate:116 t/day:Þ Solids 23 t/day at 20% dmÞ Liquid 93 t/day at 2.5% dm

Objectives

• Use all 1147 kW of heat within the AD process.

• Optimise plant Opex through claiming of RHI.

• Optimise plant Totex by smarter AD processing.

First Step: Digester Heating

Digester

CHPBiogas

Heat

Calculated thermal energy requirement: 100 kW

1147 – 100 = 1047 kW Left for further use

100 kW

Second Step: Pasteurisation 70 ºC + 1 HR

Digester

CHP

Pretreatment

Feedstock

Biogas

Heat

DPS Heat

100 kW

Without heat recovery:

51 t/day = 2,125 t/hr

Heating from 20 to 70 ºC:

Thermal energy requirement:

117 kW

117 kW

Second Step: Pasteurization 70 ºC + 1 HR

Pasteurisation with energy recovery:

Preheating

Heating

Holding

Cooling

20 ºC

50 ºC

70 ºC

70 ºC

40 ºC

60 ºC30 ºC

Heating from 20 to 50 ºC for free using heat recovery.

New thermal energy requirement:

47 kW

1047 – 47 = 1000 kW Left for further use

PASTEURISER INSTALLATION

Third Step: Digestate Concentration

• Use evaporation process to concentrate digestate.

• Use thermal heat to bring digestate to boiling point and evaporate water out of the digestate.

• End result: concentrated digestate & evaporated water.

Third Step: Digestate concentration

1000 kW can evaporate 2700 kg/hr of water.How? Two stage vacuum evaporation:

First Stage Second Stage3.9 t/hr 1.2 t/hr2.6 t/hr

Steam 65 ºC

CHP heat 90 – 70 ºC Evaporated water 2.7 t/hr

2.5 % 8.1 %3.8 %

DIGESTATE CONCENTRATION INSTALLATION

End Result

Digester

CHP

PretreatmentFeedstock

Biogas

DPS

100 kW

117 kW

MechanicalSeparation

Compost DCS

1000 kW

Concentrated liquid digestate

Evaporated water

Conclusions

Advantages of capturing heat efficiently:

• 1047 kW RHI claim !!! Est.£210k• 23,652 tonnes of digestate not tankered off site.Est. savings £200-300k (dependant on deal done).• Efficient Pasteurisation.• Concentrated digestate: added value fertiliser.• Evaporated water used for digester feed make up.

THANK YOU.

WANT TO KNOW MORE? STAND D501www.hrs-heatexchangers.com

[email protected]

http://www.hrs-heatexchangers.com/


TRIOGEN

How to increase AD power plant electrical efficiency converting exhaust gas heat into powerUK AD & Biogas 2016 Conference

ADBA Birmingham 6 July 2016

GREEN ELECTRICITY FROM WASTE HEAT

310

AD powerplant engine energy balance

Circa 40% of the heat input is converted in electricity

The engine jacket cooling water can be used for suitable heat utilities

Circa 30% is left to recover in the exhaust gas heat content!

*Typical AD powerplant data

311

AD plant energy balance

Using an exhaust gas to water heat exchanger it is possible to increase the plant total efficiency

There are also alternative ways to recover the exhaust gas heat content

*Typical AD plant data

Triogen waste heat recovery

Utilizes exclusively the heat content of the exhaust gases, the jacket water is not required

Increases the electrical output and revenue by approximately 10% Does not influence the engine performance

No extra fuel or C02 emissions

Triogen: the technology

• The Organic Rankine Cycle (ORC) is an alternative to the conventional steam cycle

• Electrical output ranging from 80-170kWe

• Certified for unsupervised operations (Lloyds Register)

• Limited sensitivity to ambient temperatures

• 97% availability consistently demonstrated

• High part-load efficiency

Triogen: the technology

Easy to install both on retrofit and new installations

Triogen ORC: products

AD plant energy balance with Triogen ORC

Our Vision: In 20 years, ORCs will be as common in internal combustion engines as turbo chargers are today.

AD plant: case studies

Location NL UK

Engines 2 x JMS316 1 x JMS612

Power before ORC 1670 kWe 1458 kWe

Exhaust gas use before ORC 100% rejected to atmosphere

100% rejected to atmosphere

ORC Power 160 kWe 132kWe

Installation year 2009 2015

Increase power revenue 9.6% 9.1%

Availability 94% 92.7% (99.5% in the last 4 weeks)

3 units fully commissioned in

the UK

Application Areas - examples

Steel Industry

Biogas Plants Mine Gas

Off-grid generation

Landfill Gas

Biomass Combustion

Flares Chemical Industry

Glass IndustryCHPs Waste Incineration

ü

ü

ü

ü = installed/sold

Internal Combustion EnginesProcess Heat /

Direct Combustion

Shipping

ü

ü

ü

The References

ORC units running with engines on:• landfill gas• Biogas • bio-diesel• mine gas• sewage gas• flare gas

ORCs running with furnaces:• solid biomass

>500,000 operating hours from 40 units

Page 319Mar-16

www.triogen.nl

Anaerobic Digestion and Heat: Policy and Market Overview

Dr Barney McManigal

23 June 2016

Agenda1. About the ADE2. Using Anaerobic Digestion with Combined Heat

and Power and District Heating3. Government’s role so far4. DECC’s Heat Networks Investment Project

(HNIP): £320m5. Support for renewable heat

ADE visionThe voice for a cost effective efficient, low carbon,

user-led energy system; a market in which decentralised energy can flourish

Areas of focus:Combined heat and powerDistrict heating and coolingDemand side energy services

Demand side

services

CHPDistrict Heat

How to capture and use heat from Anaerobic Digestion effectively?

Why use heat from AD?

Combined heat and power efficiency

Making sure CHP is done rightCHP only provides benefits when it is installed and operated properlyReputation risk to all parts of supply chain

Read and use CIBSE’s AM-12 GuidanceEnergy audit to see if CHP right solutionUse reputable CHP supplier, with O&M contractHandover with business energy users

Accessing lower carbon technologies

District heating: BenefitsAccess a wider range of heat generation technologiesGenerate heat more efficiently, lowering energy costsReduce labour and maintenance costs Reduce CO2 emissions Security of powersupplies for growing communitiesDirectly tackle fuel poverty and cold homes

District heating in the UK

Current:405,000 dwellings~4% heat demand

Government ambition to grow to 20% ofheat demand by 2030, where suitableHeat networks are not the right solution in all places

Heat Networks Delivery Unit (HNDU)Created in 2013 to provide specialist guidance provided to LAsHeat-mapping, master-planning, feasibility studies, project developmentOver £11m funding – Supporting 201 heat projects across 118 local authorities45 HNDU-supported projects are now seeking up to £480m in capital investment (Heat Infrastructure Investment Pipeline) UK wide: 280 heat network projects ready for investment (up to £2 billion)

New funding announcedThe Chancellor said at the November 2015 Spending Review:

“The Government will provide over £300m of funding on heat networks over the next five years …..

leveraging around £2bn of private and local capital investment. ….”

“… this investment support is expected to lead to the construction of some 200 large heat networks in

towns, cities and communities across England and Wales heating commercial offices, public sector

buildings like hospitals and schools, as well as flats and houses, by 2025.”

HNIP EligibilityFirst funding round - who can apply?

Sponsors and owner operatorsTranche 1: Local Authorities and the public sectorTranche 2?: Private sector and community

What kinds of heat networks?New heat networks, expansions, refurbishments, interconnections, heating networks, cooling networks, heat networks that generate electricityWaste heat sources must already exist

Support for renewable heat

What next for renewable heat?Contracts for Difference (CfD)

Pays a subsidy for every MWh of electricity, varies based on average wholesale priceAuction expected in 2016, and two further auctions this Parliament. No dates have been set. No commitment yet to technologies and budgets in those auctions

Small-scale Feed-in TariffFixed subsidy for every MWh of electricity for <5 MW plantConsultation proposes cutting subsidy, removing it for >500kW plant

Renewable Heat Incentive (RHI)Consultation currently being considered. Decision expected this summer.

Tariff Guarantee?New tariffs?

Thank you

[email protected]: @theade_UK, @barneymcmanigal


www.eisenmann.com© Eisenmann SE 2015

“Efficiency is sustainability in Eisenmann plants"for agriculture, biowaste and sludges

Eisenmann Anlagenbau GmbH & Co. KG – Eisenmann Italy – Birmingham 06 07 2016

337

Contents

1 This is Eisenmann

2 Efficiency is sustainability

3 Biogas plants for agriculture

4 Biogas plants for biowaste

5 Pyrobustor

338

This is Eisenmann

Eisenmann is a leading global provider of industrial solutions and services for surface finishing, material flow automation, thermal process technology and environmental engineering.

Family owned company since its foundation in Stuttgart in 1951 Plant design and construction experts (> 60 years of experience)

Project volumesThe projects handled by Eisenmann range from conversions with a volume of less than 100,000 Euros to major installations worth hundreds of millions.

339

Factsheet

No.1 in the world market for paint shops for plastic parts

No.1 in the world market for munitions disposal plants

774,9 Mio. € in sales revenue in 2013

More than 1,500 engineers and technicians

3.774 employees (2014)

21 locations worldwide

340

Paris

São Paulo

Fuzhou

Kunshan

Shanghai

Cruzeiro Chennai

DelhiThane

Changchun

Puebla

Pune

Saronno

Göttingen (Ruhstrat)

Böblingen

Holzgerlingen

Erftstadt (intec)

Stafford

Barcelona

Country with Eisenmann locationCountry with Eisenmann sales representatives

Locations

Crystal Lake

Moskau

Minneapolis

Togliatti

341

Locations in Germany

Böblingen

Eisenmann SEEisenmann Service

Production: 15,000 m² Storage: 5,000 m² Offices: 6,600 m²

Holzgerlingen

Eisenmann Anlagenbau

Assembly 1: 4.200 m² Assembly 2: 12.000 m² Pipe production: 500 m² Offices: 9.000 m²

342

Production in Böblingen

Sheet metal punching and bending

Paint shop

Sheet metal working and laser center

Sheet metal punching and bending

343

Assembly in Holzgerlingen

Conveyor Systems test center

Assembly hall 1

Preassembly of munitions disposal plant for Kambarka

Assembly hall 2

344

AUTOMOTIVE SYSTEMS

Surface finishing, body shell conveyor systems, final assembly lines, solar thermal solutions

GENERAL FINISHING

Paint shops for metal parts, plastic parts and new materials, Circular Chain and Power & Free conveyors

Pretreatment and coating systems, high-temperature technology, firing lines for ceramics, heat treatment, carbon fiber ovens

EISENMANN THERMAL SOLUTIONS

CONVEYOR SYSTEMSElectrified monorail systems, inverted electrified conveyors, intralogistics solutions, independent fork system (LogiMover)

SERVICE

Customer service, spare parts management, plant renewal, advisory services, full-service & BOT models

ENVIRONMENTAL TECHNOLOGY

Abluft- & Rauchgasreinigung, Abwasserbehandlung, Abfallentsorgung, Munitionsentsorgung, Biogasanlagen

ENVIRONMENTAL TECHNOLOGY

Exhaust air purification, waste water treatment, waste disposal, ammunition disposal, BIOGAS PLANTS

Range of Products and Services

345

Biogas History

since 2003

Biogas Plants for Agriculture

since 2008

Biogas Plants for Biowaste

D: 55 Plants I: 25 Plants CZ: 1 Plant

CH: 4 Plants D: 1 Plant FI: 1 Plant

P: 1 Plant S: 2 Plant USA: 1 Plant

346

Contents

1 This is Eisenmann




5 Pyrobustor

347

EFFICIENCY AND SUSTAINABILITY

SUSTAINABILITY IS

SOCIAL when a region, an area and a group of people get a safe and continuos supply of energy and they increase wellbeing

ECONOMIC when energy supply is organised in a efficient way

ECOLOGICAL when energy supply and consumption respect nature

ENERGETIC EFFICIENCY….THE CAPABILITY TO USE ENERGY IN THE VERY BEST WAY to get the best result..

348

EFFICIENCY AND SUSTAINABILITY…connection

Sustainability is strictly connected to efficiency…

..…sustainability has its origin in the idea of proper use of natural resources…..

….one of these resources is ENERGY …..

More energy is EFFICIENT, more SUSTAINABILITY idea can be powerful !!!!

349

Contents

1 This is Eisenmann




5 Pyrobustor

350

Design

3D-modelling of a agricultural biogas plant

351

Agricultural biogas plants consist of…

Receipt and feeding systems for solid and liquid substrates

Main digester (1st digestion step in a horizontal plug flow digester)

Post digester (2nd digestion step in a vertical stirred tank reactor)

Separator Digestate storage tank CHP / biogas upgrading

Specific featuresModular design.Plants are easily expandable at any time.

Design

Substrate pretreatment

Main digester Pump

Preliminary pit

Separator

CHP

Digestate storage tank

Gas dome

Electricalenergy

Thermal energy

Fertilizer

Pump

Post digester

Biogas

Processheat

Process heat

352

Dry fermentation

CharacteristicsHigh dry matter content in the digester DM-content ≥ 12 %

Specific featuresRobust plant technology necessary.All substrates can be utilized.

Eisenmann biogas plants for biowaste are dry fermentation plants.

Biowastepretreatment

Digester Pump

Compost

Separator

CHP

Digestate storage tank

Liquid substrates

electrical energy

thermal energy

compost fertilizer

353

BIOGAS PLANTS FOR AGRICULTURE

354

Design

The agricultural biogas plants are based on a two-stage process, with a main and post digester. Made-to-measure biogas plants can be developed by combining multiple main digesters.

Agricultural biogas plants with main digester volumes of… 270 m³ 325 m³

The post digester volumes are adapted to individual needs.

355

Eisenmann plug-flow digester for substrates with high solids content.

Insulated and heated steel digester with horizontal agitator

Plug-flow digester

356

Motor + trasmission for a slow continuous movement…less inrush currents respect to traditional mixers!! Less electrical autoconsumption….

Motor + transmission allows to have an EFFICIENT SYSTEM

Plug-flow digester

357


Plug-flow digester

Gas dome with safety installations, sand discharge for the removal of sinking layers, recirculation pipe

358

Plug-flow digester

sand discharge for the removal of sinking layers

Easy operational management means less biogas loss of production

If the system always works right……customer save money

EFFICIENCY!!

359

Combined heat and power (CHP) plant

Biogas-driven combustion engine powers generator that produces electrical energy.

Electrical energy – to be fed into the national gridWaste heat – for heating the digesters and for other uses CHP IS EFFICIENCY …

360


Bologna (BO) - Nominal electrical power 500 kW- substrates: sailage, slurry,..

…CHP IS EFFICIENCY especially if energy of hot water is used for a heating grid to warm houses or industry

361

Trionfi-Honorati – Ancona, Italy

Year of construction: 2009Substrates: Cattle slurry, cattle manure,

dry chicken manure, olive pomace, straw and hay, grass and maize silage

Substrate throughput: 9,000 t/aMain digester volume: 1 x 270 m³Post digester volume: 750 m³Nominal biogas flow rate.: 120 Nm³/h

Post and main digester Substrate mixer, main digester, CHP and post digester

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Patens s.r.l. – Cremona, Italy

Year of construction: 2010Substrates: Slurry, chicken manure, silages,

olive pomace, wastes from the animal

feed industry, liquid organic wastes

Substrate throughput: 12,000 t/aMain digester volume: 2 x 325 m³Post digester volume: 2.000 m³Nominal biogas flow rate: 280 Nm³/h

Post and main digester with substrate mixer Main and post digester with inspection platform

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Co.Pro.B. – Finale Emilia, Italy

Year of construction: 2012Substrates: Sugar beets, molasses

and maize silageSubstrate throughput: 22,500 t/a

Main digester volume: 3 x 325 m³Post digester volume: 2,900 m³Nominal biogas flow rate: 480 Nm³/h

Substrate mixer, main digesters and post digester Main digesters and post digester with inspection platform

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Contents

1 This is Eisenmann




5 Pyrobustor

365

BIOGAS PLANTS FOR BIOWASTE

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Design

3D-modelling of a biowaste digestion plant

Substrate pretreatment and feeding

Digestion stage

Digestate output

Separation Digestate storage tank CHP/ biogas upgrading

367

Gentle and rapid breakdown of material by means of fast rotating, low-wear chains.

Cross-flow shredder

Coarse comminution, unpacking, prevention of over-comminutionSuitable for: standard biowaste bin

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Fast comminution of lumpy, inhomogeneous and packaged materials by means of roller cutters.

Two shaft shredder

Comminution, unpackingSuitable for: standard biowaste bin, garden waste and landscape conservation material

Source: Komptech GmbH Source: Komptech GmbH

369

Star elements mounted on shafts loosen the material, separate out the fine and remove the coarse material.

Star screen

Loosening, screening, separation of foreign matter, conveyingSuitable for: standard biowaste bin, garden waste and landscape conservation material

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Fine grinding and homogenization by means of free-swinging steel hammers mounted on a rotor.

Hammer mill

Fine grinding, pre-milling, can separate out foreign matterSuitable for: wastes from food production and agro-industrial sector, food and slaughter waste

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Push-floor system for pre-storage and continuous material feeding.

Push-floor container

Pre-storage, buffer storage, scales, material feeding systemSuitable for: all kinds of solid and bulk biowaste

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Range of sizes, precast concrete elements or in-situ concrete, insulated, internal heating system, access doors, horizontal agitator shaft, double membrane gas storage roof

Plug-flow digester

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Eisenmann agitator for continuous movement and optimum gas yield from the substrate.

Horizontal agitator

External bearings, no central bearing, low speedSuitable for: substrate mixtures with high solids

EFFICIENT DESIGN OF PLATES

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Biogas-driven combustion engine powers generator that produces electrical energy.

Electrical energy – to be fed into the national gridWaste heat – for heating the digesters and for other uses

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Västblekingemiljö AB – Mörrum, Sweden

Year of construction: 2012Substrate: Biowaste, green wasteSubstrate throughput: 20,000 t/a

Digester volume: 2 x 800 m³Nominal biogas flow rate: 260 Nm³/h

3D model Double rectangular digester with push-floor containers

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Kelsag Biopower AG – Liesberg, Switzerland

Year of construction: 2010Substrates: Cattle slurry, biowaste,

garden waste, wastes from food production

Substrate throughput: 12,000 t/aDigester volume: 800 m³Nominal biogas flow rate: 150 Nm³/h

Main digester and final storage tank Biogas pipeline

377

Bioenergie Bätterkinden AG – Bätterkinden, Switzerland

Year of construction: 2010Substrates: Cattle slurry and manure, garden

waste, fruit and vegetable waste, wastes from food production

Substrate throughput: 8,000 t/aDigester volume: 800 m³Nominal biogas flow rate: 150 Nm³/h

Aerial view of entire plant Biogas pipeline

Source: sol-E Suisse AG

378

Labio Oy – Lahti, Finland

Year of construction: 2015Substrates: biowaste organic collection fraction

dewatered sludges

Substrate throughput: from 26.000 to 44.000 t/aDigester volume: 4 x 900 m³Nominal biogas flow rate: 900 – 1300 Nm³/h

Aerial view of entire plant Biogas production

FLEXIBLE = EFFICIENT!!

379

CR&R – Perris - California, USA

Substrates: high solid organic wastegreen stuff

Substrate throughput: 80.000 t/a

up to 320.000 in the futureNominal biogas flow rate: 900 Nm³/h

view of entire plant

Trucks methane vehicles

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Contents

1 This is Eisenmann




5 Pyrobustor

381

PYROBUSTOR in San Lorenzo di Sebato – Bolzano - Italy

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PYROBUSTOR plant in a integrated process

1 - 2 - 3 - 4 Water treatment plant

5Digesters

6Gas storage

7 office

8Pyrobustor area

8

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PYROBUSTOR

384

PYROBUSTOR…EFFICIENCY!!!!

EFFICIENCY!!

385

PYROBUSTOR

386

PYROBUSTOR

387

PYROBUSTOR

388

PYROBUSTOR

GOOD RESULT EFFICIENT SYSTEM

389

PYROBUSTOR

WHY PYROBUSTOR IS SUSTAINABLE?

390

PYROBUSTOR

SOCIAL SUSTAINABILITY

130.000 people (resident and tourist) benefit by the plant!!

391

PYROBUSTOR

ECONOMIC SUSTAINABILITY

Saving money!!!

Ashes with < 5% carboncontent and recycling

Safety for operators !!!

392

PYROBUSTOR

ECOLOGICAL SUSTAINABILITY

Respect for nature !!

393

CONCLUSIONS

if we all manage to create EFFICIENT SYSTEMS and plants….

….if we all try to live EFFICIENT LIFE…..

…we help the world to be more SUSTAINABLE FOR……

394

PYROBUSTOR

THANKS

FOR

YOUR ATTENTION

LINKING AN AD PLANT TO A DISTRICT HEATING NETWORKSteve Richmond – Head of Marketing & Technical, REHAU Ltd - ADBA Show 6.7.2016

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20,000 employees worldwide – experts in polymer manufacturing

Since 2000, involved in thousands of district heating projects across Europe

Manufacturer of district heating pipes & fittings

Largest UK stock of district heating pipe

REHAU’s experience of district heating

396July 2016 / Rowy 2642/ BT GB

REHAU are the only UK-manufacturer of PE-Xa district heating pipe. Production started in May 2012. Est. 30% reduction in CO2 from UK manufacturing.

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RAUVITHERM

-PEX foam (non-bonded)-Only PE-Xa pipe made in the UK-Very flexible – easy to install-Coil lengths up to 330m-Available up to 160mm

REHAU’s district heating solutions

398July 2016 / Rowy 2642/ BT GB

-PU foam (bonded)-Best in class heat losses (0.0216WmK lambda)-Largest coiled pipe (140mm in 70m)-Largest DUO pipe (75 twin)-Available up to 160mm

RAUTHERMEX

What is district heating?

Instead of individual boilers in each home, you have one large external boiler. Pre-insulated pipes then transport the heat to the buildings.

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- Large carbon savings possible

- Economies of scale – increase efficiency

- Ideal for technologies not feasible on individual properties (e.g. AD plants)

- Future proof – easy to change fuel source

- Minimise maintenance using one central plant – no individual gas checks required

What are the benefits?

400February 2015 / Rowy 2642/ BT GB

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Energy savings for a typical domestic property

401July 2016 / Rowy 2642/ BT GB

Technology Cost (£/MWh) Carbon savings (kg/a) over baseline

Baseline gas boiler 70 0

Air-source heat pump 110 -100

Ground-source heat pump 130 500

Small scale DH network 120 3,500

Large scale DH network 100 4,200

Anaerobic digestion CHP 215 5,900

Source: Powry / AECOM report for DECC – April 2009

District heating currently only supplies ca. 2-3% of the UK’s heat demand – far below countries like Denmark (63%) & Germany (14%)

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Most UK AD plants were built for electricity generation.

Selling this waste heat to local consumers allows:

- Extra income stream- Receive Renewable Heat Incentive (RHI) payments for 20 years- Increases the efficiency of the biogas CHP (from ca. 40% to 80% efficiency)

Why use the waste heat of an AD plant?

403July 2016 / Rowy 2642/ BT GB

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- In rural areas the pipes can be installed in ‘soft-dig’ areas

- Often AD plant owners can install the pipes themselves

- Rural heat consumers are often on oil / LPG / electric heating and can achieve significant fuel savings

- AD plants have high capital costs – the heat income & RHI income can support the business case

Why is farm-based AD ideal for district heating?

404July 2016 / Rowy 2642/ BT GB

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UK case studies of bioenergy projects

405July 2016 / Rowy 2642/ BT GB

- Gaunts Estate – AD - 1.6km network

- Soho luxury cottages – Biomass - 7km network

- Much Fawley Farm – AD - 2.5km network

- Bluestone Park – Biomass - 2km network

- Sanderson plant, Yorkshire – AD – 1.5km network

Can polymer pipes be used for a large scale heat network? REHAU supplied 80km of RAUTHERMEX to the bioenergy village of Lathen in Germany of 11,000 residents.

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UK production: Only UK manufacturer of PE-Xa district heating pipes.

REHAU - Your expert partner in district heating

407July 2016 / Rowy 2642/ BT GB

Quality: The renowned REHAU Everloc™ jointing system has been used over 850 million times.

Local UK sales & technical teams: On-site support from specialist DH sales team (4 regional offices + UK head office)

Design service: Experts in heat network optimisation and design.

Largest UK stock & full cutting service: No 4-6 week wait for an urgent fitting!

BIM: REHAU’s district heating pipes have BIM models ready for download.

THANK YOU FOR YOUR ATTENTIONAny questions?

Contact details:[email protected] 405948