Digestates From Anaerobic Digestion A Review of Enhancement Techniques and Novel Digestate Products - 0

Desk top study on digestate enhancement and treatment
Enhancement and treatment of

digestates from anaerobic digestion
A review of enhancement techniques, processing options and novel

digestate products
Project code: OMK006 - 002

Research date: Feb 2012 May 2012
Date: Nov 2012
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Executive Summary
Background
Anaerobic digestion (AD) is a well established process for the treatment of organic wastes
and the generation of renewable energy. Historically the digestate produced from the
process has been applied to land as a fertiliser or soil conditioner. However with a planned
increase in the number and capacity of AD plants to treat a variety of organic waste streams
in the UK, digestate enhancement technologies are gaining more attention.
Digestate enhancement technologies could be assessed by an AD operator looking to provide
any of the following options for an AD plant:
increase the value of digestates;
secure use of digestates;
create new markets for digestate products; and
decrease the operating costs (OPEX) of the facility.
Objectives
This study aims to identify digestate enhancement technologies and techniques, in order to
raise awareness of them within the UK waste sector. The study has considered well
established techniques, as well as novel or emerging processes currently under development.
The project has reviewed technologies applicable to all digestates produced from the
anaerobic digestion of a variety of feedstocks, whether or not they are compliant with PAS
110 or the Anaerobic Digestion Quality Protocol (ADQP).
A key objective of the study is to raise awareness in the UK waste sector to the opportunities
and challenges of digestate enhancement.
The output of the study supports the delivery of a number of actions contained in the AD
Strategy and Action Plan (June 2011) and the delivery of Scotlands Zero Waste Plan.
Methodology
Data has been collected from an extensive desk based literature search, direct contact with
technology providers, relevant industry focus groups, academic research, conference papers,
policy documents, relevant industry texts and manufacturers literature and legislation. A
web-based search was also undertaken. This information has been used to construct
technical data sheets for each technology considered which form an appendix to the report.
In addition a number of examples of applications of novel technologies have been included
in the report.
Enhancement and treatment of digestates from anaerobic digestion
Findings
This study has found that there are a wide range of technologies available for digestate
enhancement. Technologies are available to create a range of novel digestate products such
as concentrated or balanced fertilisers, which have the potential to be marketed as
products.
However, no single technology has been found to be relevant for all applications so a range
of solutions will be required to accommodate the increasing volumes of digestate generated
within the UK.
From an EU waste sector perspective, there are clearly similar challenges and goals to the
UK waste sector; but AD investment in Europe has been driven by a series of different
drivers and supported via different energy subsidy regimes. EU funded support of the
research and development of digestate products and markets has assisted EU member states
in making investment decisions over the last ten years. Research and development
continues with a focus on the development of enhanced products.
UK markets for waste derived digestates are immature. There is existing competition in land
based markets, not least with conventional inorganic fertilisers. However, in the future as
natural phosphorous resources decrease and the cost of inorganic fertilisers increase,
farmers will look to find alternative and potentially cheaper sources of nutrients for their
crops.
The key challenge in the short term will be to manage increasing quantities of digestates
seeking markets and secure outlets. Operational experiences should be sought from the EU,
where systems have been installed and digestate products created to satisfy outlet demand.
Contents
1.0
2.0
3.0
4.0
5.0
6.0
7.0
Introduction ................................................................................................. 1
1.1
Objectives ................................................................................................. 2
1.2
Aims ......................................................................................................... 2
Methodology ................................................................................................. 3
Digestate Enhancement................................................................................ 4
3.1
What is Digestate? ..................................................................................... 4
3.2
Why Use Enhancement Techniques? ............................................................ 4
Digestate Enhancement................................................................................ 6
4.1
Pre-Digestion Enhancement Techniques ....................................................... 6
4.1.1 Thermal Hydrolysis........................................................................... 6
4.1.2 Autoclave Systems ........................................................................... 6
4.1.3 Enzymic Liquefaction ........................................................................ 7
4.1.4 In-Vessel Cleaning Systems .............................................................. 7
4.2
Post-Digestion Enhancement Techniques ..................................................... 9
4.2.1 Physical Enhancement Techniques................................................... 12
4.2.2 Thermal Enhancement Techniques .................................................. 14
4.2.3 Biological Enhancement Techniques ................................................ 16
4.2.4 Chemical Enhancement Techniques ................................................. 20
Digestate Enhancement Systems ............................................................... 23
5.1
Digestate Treatment Systems.................................................................... 23
5.2
Digestate Enhancement Systems ............................................................... 26
5.3
Current Barriers to Enhancement Systems .................................................. 27
5.4
Technology Example: Barkip Biogas Facility ................................................ 28
5.4.1 Background ................................................................................... 28
5.4.2 Process Description ........................................................................ 29
5.5
Technology Example: Lee Moor EFW ......................................................... 30
5.5.1 Background ................................................................................... 30
5.6
Technology Example: MINORGA Bio fertiliser, Norway .............................. 32
5.6.1 Background ................................................................................... 32
European Perspective ................................................................................. 35
6.1
Background ............................................................................................. 35
6.2
Survey Data............................................................................................. 35
6.3
Transport Optimisation ............................................................................. 36
6.4
Summary of EU Waste Sector.................................................................... 37
Summary .................................................................................................... 38
Glossary
AD
Anaerobic digestion. Process of controlled decomposition of organic matter under

anaerobic conditions.
Aerobic
Molecular oxygen available.
Anaerobic
No oxygen source..
Anaerobic Digestion
Quality Protocol (ADQP)
End of waste criteria for the production and use of quality outputs from anaerobic
digestion of source segregated biodegradable wastes.
Anoxic
No available source of molecular oxygen.
Auto thermal
Condition at which an exothermic reaction is self sustaining and no additional energy is

required from an external source.
Bio methane
Methane generated by anaerobic digestion.
Biogas
Gas generated by an anaerobic digestion process. Typically composed of 60% methane

and 40% carbon dioxide.
BOD
Biological oxygen demand. Defined as the amount of oxygen required by aerobic

bacteria to oxidise the organic matter within the sample.
CAPEX
Capital expenditure.
CH4
Methane.
CHP
Combined heat and power. Cogeneration of heat and power from combustion of a
fuel(gas).
COD
Chemical oxygen demand. Defined as the amount of oxygen required to chemically

oxidise the organic matter within the sample.
Digestate, Fibre
Fibrous fraction of material derived by separating the coarse fibres from the whole
digestate.
Digestate, Liquor
Liquid fraction of material remaining after separating coarse fibres from whole
digestate.
Digestate, Whole
Material resulting from an anaerobic digestion process that has not undergone postdigestion separation.
Dry solids (ds)
Measure of solids content within the digestate. Defined as the % of mass remaining
after drying at 105C.
Evapotranspiration
The combined effect of evaporation and plant transpiration (normal water loss to the
atmosphere from plants).
H2S
Hydrogen sulphide.
MBR
Membrane bioreactor. The combination of a membrane process with a suspended

growth bioreactor.
MBT
Mechanical Biological Treatment: waste processing facility that combines a mechanical

sorting facility with a form of biological treatment such as composting or anaerobic
digestion. MBT plants are typically designed to process mixed wastes and as such are
not capable of achieving PAS 110 or PAS 100.
Moisture content
Measure of water content within the digestate. Defined as the % of mass lost after
drying at 105C.
NH3
Ammonia.
OPEX
Operating expenditure.
Pasteurisation
Process step during which the number of pathogenic bacteria, viruses and other harmful
organisms in material are significantly reduced or eliminated by heating the material to
a critical temperature for a specified period of time.

PAS 100
Publically Available Specification that controls the quality input to compost and the
process is managed and operated to generate composts that protects the environment
and meets market needs.
PAS 110
Publically Available Specification that controls the quality input to anaerobic digestion
and the process is managed and operated to generate digestate that protects the
environment and meets market needs.
Polyelectrolyte
High molecular weight organic polymer used to assist flocculation in solid liquid
separation.
RHI
Renewable Heat Incentive. Financial incentive for the use of renewable heat.
RO
Reverse Osmosis: A membrane filtration technology that utilises a selective reverse

osmosis membrane to retain molecules and ions while allowing the solvent, ions and
small soluble molecules to permeate through.
ROC
Renewable Obligation Certificate. The main financial support mechanism for large
renewable electricity projects in the UK.
Sanitisation
Biological process that eradicate or reduce pathogens to acceptably low, sanitary levels.
Syngas
Abbreviation of synthesis gas. Gas mixture that comprises of carbon monoxide, carbon
dioxide and hydrogen produced by the gasification of a carbon containing fuel.
UF
Ultra Filtration: A membrane filtration technology that utilises a selective ultrafiltration

membrane to retain soluble macromolecules and larger contaminants while allowing the
solvent, ions and small soluble molecules to permeate through.
Acknowledgements
The authors would like to thank the various organisations who provided information and
advice on digestate enhancement systems. Particular thanks to Tim Evans (Tim Evans
Environmental Ltd), Nigel Horan (Aqua Enviro), Paul Bardos, Claire King and Ursula Kepp (r3
Environmental Ltd), Steve Wooler (HRS), Oddvar Tornes (IVAR IKS), Christian Toll
(AeroThermal), Mike Weaver(Pyreg), Tobias Finsterwalder (FIMTEC GmbH) and Ian
Crummack (DONG Energy).
1.0 Introduction
The use of anaerobic digestion (AD) to recover value from organic wastes within the UK is
emerging as an important treatment system and is forecast to increase significantly. There
are currently 233 AD plants operating within the UK with a capacity to treat 5.4 million
tonnes of material:
51 AD facilities operating on waste including food waste.

36 AD facilities operating on farm waste.
146 AD facilities operating on sludge generated by waste water treatment works.
There are currently planning applications to develop a further 222 facilities in the UK
(1WRAP held data, Nov 2012) which will provide for significant increase in processing
capacity.
AD converts organic matter into biogas, a source of renewable energy, and a nutrient rich
organic fraction known as digestate. Biogas can be used to generate electricity and heat to
power the process. Excess power can be sold to the National Grid and excess heat can also
be utilised, if the right infrastructure exists. The most commonly used digestion system is
wet mesophilic digestion operating between 25C and 40C; the digestate produced from
this process is an organic slurry, rich in nutrients such as nitrogen and phosphorus. Other
less common systems include dry digestion, which uses a feedstock with very high dry solids
content and thermophilic digestion, which operates at higher temperatures (50C - 60C).
Currently the majority of AD facilities recycle the digestate to local agricultural land as an
organic fertiliser (Fuchs et al., 2010). However the window for land application is limited to
agricultural and crop requirements (Orr, 2011), and for large capacity AD plants, a
substantial area of land is required to provide a secure and suitable market for the
digestate. If application to agricultural land is not feasible, due to transport distances,
legislative requirements or other restrictions, digestate can be used for land reclamation.
This is particularly relevant for digestates from mechanical biological treatment (MBT)
applications, as the use of digestates derived from mixed waste materials is currently
restricted to use on land restoration projects only.
As the use of AD increases the demand for agricultural land will also increase, potentially
requiring plants to transport digestate further in search of suitable land. This is important
for the increasing number of centralised AD facilities operating in urban areas. Digestate
must therefore be carefully managed to ensure it is utilised as a resource and maximum
benefit is achieved whilst avoiding excessive transportation costs.
Whilst the data is accurate to the best of WRAPs knowledge, WRAP offers no warranty and accepts no liability relating to the
completeness or accuracy of the information contained within. Information is compiled by various parties and recipients should
make their own independent enquiries before relying on the information contained within the document.
1.1
Objectives
WRAP has acknowledged the need to raise awareness of digestate enhancement

technologies to secure land application or develop novel products which is the key objective
of this study and is a key action in the AD Action Plan. The study focuses on digestate
produced from anaerobic digestion processes that cover:
both non-waste and waste-based digestates, whether or not they are compliant with
PAS 110 or the Anaerobic Digestion Quality Protocol (ADQP);
mixed-waste digestates as the output from Mechanical Biological Treatment (MBT);
amended sludge digestates or co-digestates, derived from feedstocks including
sewage sludge; and
sludge digestates (biosolids), solely derived from sewage sludge.
1.2
Aims
The aim of this study is to identify technology and techniques for the enhancement of
digestate from straightforward dewatering to the development of novel products. The
project has reviewed technologies and enhancement techniques applicable to all digestates
produced from the anaerobic digestion of a variety of both waste and non-waste feedstocks,
whether or not they are compliant with PAS 110 or the Anaerobic Digestion Quality Protocol
(ADQP).
The output of the study is to support the delivery of a number of actions contained in the
AD Strategy and Action Plan (June 2011) and the delivery of Scotlands Zero Waste Plan.
It is vital that digestate enhancement is seen in a holistic way as part of an overall materials
processing and re-use system. It is important that the overall case for sustainable wastes
and resource management is not negated by inappropriate digestate management choices,
for example:
the use of downstream processing to treat digestate that consumes more energy
than is likely to be generated by the AD facility;
the generation of large volumes of effluent for treatment that create an unacceptable
overall carbon or water footprint for the AD facility;
the transmission of harmful impacts to soil and groundwater that are substantially
greater than using alternative materials such as composts or conventional fertilisers;
the reduction in carbon benefit of systems that generate high greenhouse gas (GHG)
emissions, for example the atmospheric release of methane (CH4 ) or nitrous oxide
(N2O);
the inappropriate development of AD facilities that have negative impacts on the
public perception and economic viability of digestion as an effective waste
management and energy recovery option; and
high capital and operating costs that limit the financial viability of AD and increase its
reliance on public subsidy.
2.0 Methodology
In order to identify and assess possible digestate enhancement techniques a detailed desk
based literature search has been undertaken. Sources for the literature search included
technical reports, academic research, conference papers, policy documents, relevant
industry texts, manufacturers literature and legislation. A web-based search was also
undertaken.
In addition to the literature search, information was requested from a number of anaerobic
digestion organisations and interest groups within the UK and EU. Over 30 organisations
were approached to participate and provide information for this study. A full list of
organisations contacted can be found in Appendix 1.
Unfortunately a number of the organisations contacted were unable to participate and
provide information for this study, partly due to commercial reasons or perceived conflict of
interest.
Data obtained from the research was compiled and used to construct technical data sheets
for each enhancement technique identified, which can be found in Appendix 2. The aim of
these data sheets is to provide a brief description of the operating principle of the
technology/technique, operating conditions and associated benefits, challenges and
opportunities.
In addition to developing technical datasheets, a number of example enhancement projects
have been included in the report. These focus on the application of emerging technologies
which either significantly enhance digestate quality or support the development of novel
digestate products.
3.0 Digestate Enhancement

3.1
What is Digestate?
Digestate refers to the material produced by the process of anaerobically digesting

biodegradable materials. Digestate consists of a mix of microbial biomass (produced by the
digestion process) and undigested material. The volume of digestate produced will be
approximately the same as the feedstock volume, although the mass will typically be
reduced by approximately 15%. Digestate contains all the nitrogen, phosphorus and
potassium present in the original feedstock and as a consequence has value as an organic
fertiliser. Typical nutrient values for digestate are given below, however the actual nutrient
content will be highly dependent on the type of feedstock processed (Chambers, 2011).
Nitrogen: 2.3 - 4.2 kg/tonne.

Phosphorous: 0.2 - 1.5 kg/tonne.
Potassium: 1.3 - 5.2 kg/tonne.
(NNFCC, 2012)
Consideration must be given to the relationship between the quality of the feedstock and
the quality of the digestate. The digestate will contain all material that has not biodegraded
and converted into biogas within the process, therefore any contaminants in the feedstock
will remain in the digestate. A good quality, well prepared feedstock will therefore produce a
good quality digestate compared with poor quality feedstock which will produce a poor
quality digestate.
3.2
Why Use Enhancement Techniques?
The majority of digestate produced in the UK is spread to agricultural land as fertiliser,

either as whole digestate or as a separated fibre (Fuchs et al., 2010). Although this is a
good use of the nutrients within the digestate, the value of the digestate to the producer is
low (Horan, 2012). Once the costs of transportation and spreading are taken into account
the digestate value can be close to zero, and may even be a cost to the producer (Lewens,
2011).
The application of nitrogen in organic materials to agricultural land is regulated by the
European Nitrates Directive (91/676/EEC.) (Fuchs et al., 2010). As a consequence the
spreading of digestate to land is controlled (based on nitrogen content) and dependent on
location and crop demand. This can result in digestate being transported greater distances
to find suitable land-based markets and avoid over application; this will increase transport
and operational costs. Furthermore land application is only appropriate during the growing
season, requiring digestate to be stored for significant months of the year. More
information on NVZs can be found on Defras website, http://www.defra.gov.uk/foodfarm/land-manage/nitrates-watercourses/nitrates/.
If the number of operating AD facilities increases, as currently predicted, local competition
for land based markets will also increase, with a consequential impact on transportation and
spreading costs.
The key aims of digestate enhancement techniques are to:
increase the value of the digestate;

create new markets for digestate products;
reduce the dependence on land application;
ensure more secure and sustainable outlets for digestate products; and
potentially reduce the operating cost of the facility.
Consideration has been given in this study to enhancement techniques and technologies
that can be applied at three key stages:
pre-digestion;
within the digestion process ( i.e. in-vessel); and
post-digestion.
Each system considered is aimed at supporting the objective of enhancing the quality of the
digestate or providing potential to develop new digestate products.
4.0 Digestate Enhancement

4.1
Pre-Digestion Enhancement Techniques
Pre-treatment systems employed upstream of anaerobic digestion can be used to enhance

the digestion process, and as a consequence digestate quality. There are a number of
techniques available to pre-treat the feedstock and improve the availability of organic
constituents to enhance the digestion process. In addition the removal of contaminants and
debris from the feedstock to the digestion process is key to maintain digestate quality and in
the extreme secure stable operation of the digestion process. These systems are discussed
below.
4.1.1 Thermal Hydrolysis

The thermal hydrolysis process (THP) is a high-pressure, high-temperature steam pretreatment application for anaerobic digestion feedstocks. The feedstock is heated and
pressurised by steam within a reaction tank before being rapidly depressurised (flashed).
This results in the breakdown of cell structure within the biomass; as the organic matter is
presented to the digester in a broken-down condition, the digestion process is more
effective resulting in increased gas production and improved digestate quality.
To ensure the process is thermally and economically efficient the system requires a
dewatered feedstock at between 15-16% dry solids. As a consequence dewatering systems
are an important pre-treatment stage. Details of dewatering systems are provided in Section
3.4.1. As the thermal hydrolysis process utilises a dewatered feedstock increased digester
loading is achieved and therefore gas production is increased.
The quality of the digestate is improved as the hydrolysed digestate is pasteurised, easier to
dewater and achieve higher dry solids product, resulting in a product that is easier to store,
handle and transport (CAMBI, 2011, Veolia, 2008).
The process has widespread waste water treatment applications operating on sewage
sludge. The process is being developed for organic and food waste applications in Europe,
particularly Norway.
4.1.2 Autoclave Systems

An autoclave can be used to pre-treat digester feedstocks in a similar manner to thermal
hydrolysis. The autoclave is a pressure vessel that steam treats its contents at a constant
temperature and pressure, serving to pasteurise, clean and break-down organic matter
within the feedstock. As the organic matter is presented to the digester in a broken-down
condition the digestion process is more effective resulting in increased gas production and
improved digestate quality.
After processing inorganic material and contaminants can be easily removed via mechanical
separation, providing a clean, pasteurised, organic rich feedstock for anaerobic digestion
(AeroThermal Group, 2008).
4.1.3 Enzymic Liquefaction

An enzymic liquefaction system has been developed by DONG Energy A/S. for use on mixed
waste streams prior to digestion. Called the REnescience process, the system comprises
three process stages to breakdown and separate the organic matter from within the
feedstock prior to digestion. Stage one is a non-pressurised thermal treatment utilising
either hot water or steam, which opens the feedstock to make it accessible to enzymes. In
the second stage, enzymes are added to liquefy and further breakdown the cell structure of
the feedstock. The prepared feedstock is then digested in the third stage of treatment.
Following digestion the component fractions are separated such that an organic rich liquid
for land-based application can be easily separated from inorganic material and physical
contaminants.
The system appears to be suited to the pre-treatment of mixed waste streams (i.e. MBT).
A pilot plant of the REnescience process is currently operational in Denmark where a range
of waste materials, including municipal solid waste, source segregated food waste and
sewage sludge has been processed.
A schematic diagram of the REnescience Enzymic Liquefaction Process is shown in Figure 1.
Figure 1. Schematic of REnescience Enzymic Liquefaction Process
4.1.4 In-Vessel Cleaning Systems

The inclusion of in vessel cleaning systems as an enhancement technique may not initially
appear appropriate. However, detailed consideration must be given to the nature of the
waste materials being feed into the digestion process i.e. waste containing varying
quantities of:
plastic
timber
fibres (both natural and man-made textiles),
grit/sand/soil
metal fragments
solid fruit residues(pips/stones/stalks/peel)
Whilst the digestion process itself utilises significant mixing and agitation, the digestion
vessel will act as a repository of all feedstocks. Heavy materials will tend to settle and
lighter materials will tend to float to the top of the vessel and become entrained within a
scum and foam layer.
In-vessel cleaning systems can be used to good effect to remove contaminants from the
digester, improving both digestate quality and preventing the build-up of inerts. In the
extreme, hydraulic retention time in the digestion vessel can be severely reduced if these
inerts are not removed. This can lead to impairment of the digestion performance and
eventually potential process instability.
Floating material can become dislodged, adversely affecting the quality of digestate, and in
the extreme placing at risk the security of the land-based outlet and/or PAS 110
accreditation.
Proprietary systems have been developed to overcome these problems with in-vessel
cleaning techniques.
Grit and heavy solids material accumulating at the bottom of the digester vessel can be
directed by a rotating scraper system to the edge of the digester where it is removed and
separated from the digestate. The separated digestate is returned to the digestion process.
The separated grit/solids can be used as an aggregate amendment for construction or
potential land remediation. However the land remediation operation will require a permit
(Finsterwalder Umwelttechnik GmbH & Co. KG, 2012). A typical in-vessel system is shown in
Figure 2.
Floating material, such as plastics and rags can also be removed by a rotating skimmer.
Material is forced to the edge of the digester where it is removed and separated from any
entrained digestate. The separated digestate is returned to the digestion process and the
separated solids disposed to landfill.
Figure 2. Typical scraper system installed within a digester
4.2
Post-Digestion Enhancement Techniques
The enhancement techniques identified by the research undertaken in this report are
summarised in Table 1 below. Techniques have been divided into categories based on the
type of process employed i.e. physical, chemical or biological. Where multiple technologies
are available for the same enhancement principle (i.e. drying) these have been divided into
sub categories.
Table 1. Digestate Enhancement Techniques
Physical
Thermal
Thickening (Belt)
Drying (Rotary Drying)
Thickening (Centrifuge)
Drying (Belt drier)
Dewatering (Belt press)
Drying (J-Vap)
Dewatering (Centrifuge)
Drying (Solar)
Dewatering (Hydrocell)
Evaporation (scraped surface heat exchangers)
Dewatering (Bucher press)
Conversion (Incineration)
Dewatering (Electrokinetics)
Conversion (Gasification)
Purification (Ultrafiltration and Reverse Osmosis)
Conversion (Wet air oxidation)

Conversion (Pyrolysis)
Biological
Chemical
Composting
Struvite precipitation
Reed Beds
Ammonia recovery (Stripping + Scrubbing)
Biological Oxidation
Ammonia recovery (Membrane Contactor)
Biofuel Production (Algae)
Ammonia recovery (Ion Exchange)
Biofuel Production (liquor as process water)
Acidification
Biofuel Production (hydrolysis of fibre to Bioethanol)
Alkaline Stabilisation
Microbial Fuel Cell
The listing of enhancement techniques in Table 1 does not contain all possible treatment
types, and it is not an endorsement of those presented. However, the listing serves to
illustrate potential options and provide information obtained in this study.
The following sections of the report provide a brief description of each of the treatment
principles and how they may be employed. Further information on each of the techniques
can be found in the Technical Data Sheets included in Appendix 2.
Each Technical Data Sheet provides a schematic process flow diagram for the techniques, as
well as a brief process description. The aim of the Technical Data Sheets is to provide an
overview of the principles and objectives of each technology, as well as an indication of any
particular challenges that may need to be considered in implementing the system.
The flow sheet presented in Figure 3 provides an overview of the digestate enhancement
techniques and how these can be combined into viable treatment systems. This is not an
extensive list of treatment possibilities but highlights the principles available. The
dependencies of some technologies on pre-treatments are also captured within the
overview. For example, if thermal drying is to be employed the flowchart indicates that
dewatering is likely to be required as a pre-treatment. Dewatering will produce a liquor
stream which must also be treated, by membrane purification for example.
Depending on local site conditions and requirements, the number of techniques required
and the complexity of the treatment processes can vary considerably. This is discussed in
more detail in Section 5.
Given the dependencies between the technologies, digestate enhancement system design
must be approached holistically. The available outlet must also be considered along with the
demand for digestate products. For example, if nutrient recovery is to be employed a market
for the recovered products must be secured.
Once the desired outputs have been established a choice of process/technology can be
made. It is likely that a number of different technologies will be available for selection and
at this stage a detailed cost benefit analysis will be required in order to determine the
preferred solution on a site specific basis.
10
Figure 3. Overview of Digestate Enhancement and Treatment Techniques

Digestate
Microbial Fuel
Cell
Energy Recovery
Acidification
Drying
Land
Application
Land
Application
Land
Application
Wet Air
Oxidation
Reed Beds
Land
Application
Further
treatment
Energy Recovery
Dewatering
Land
Application
Liquor
Biological
Oxidation
Algae Production
Biofuel
Discharge to
watercourse /
further
treatment
Discharge to
watercourse /
further
treatment
Fibre
Nutrient
recovery
Concentrated
Fertiliser
Notes
*Ash recovery and product development required
**Residual carbon product development required
Purification
(UF + RO )
Land
Application
Products / benefits
Composting
Alkaline
stabilisation
Enzymatic
hydrolysis
(Biofuel)
Land
Application
Concentrated
Fertiliser
Land
Application
Enhancement / treatment process
Evaporation
Direct
discharge to
watercourse
Nutrient addition
Balanced fertiliser
Land
application
Land
Application
Drying
Land
application
Pyrolysis
Incineration
Energy Recovery
Char disposal
Ash Disposal*
Land
application
Gasification
Energy Recovery
Residual carbon
disposal**
11
4.2.1 Physical Enhancement Techniques

Physical enhancement techniques can be used to separate the solid and liquid fractions of
the digestate. The separated liquid fraction is termed digestate liquor and the separated
solid fraction is referred to as digestate fibre. This simple first step enables the separated
fractions to be treated individually, providing a wider range of subsequent treatment
options. The physical techniques considered in the study can be broadly split into three
categories - thickening, dewatering and purification.
These physical techniques are well established in waste water treatment; thickening and
dewatering applications are the conventional approach to reducing the volume of digestate
for subsequent storage, treatment processes or transport off site. The application of these
physical techniques may be considered a natural progression into AD facilities and have
potential for retro-fitting to existing plant.
Thickening
Thickening is a term used to describe the partial separation of the solid and liquid fractions
to achieve a digestate of 5 10 % dry solids and a separated liquor. At this solids
concentration the digestate is a thick liquid. Thickening is typically employed as an initial
pre-treatment stage to reduce the volume of the digestate for subsequent storage.
Increasing the solids concentration not only reduces the volume but can also improve
downstream processing in terms of throughput capacity and associated electrical and
chemical consumptions.
Often polyelectrolyte can be added to digestate to improve coagulation and increase the
overall solids capture and operability of the thickening system (Evans, 2008). Increasing
solids capture is important to ensure the separated liquor does not impose a high biological
treatment demand on waste water treatment systems.
Dewatering
Dewatering is a term used to describe the separation of the solid and liquid fractions of
digestate to achieve a separated fibre content typically greater than 18% dry solids and a
separated liquor. When whole digestate is dewatered, 80% of the mass is removed in the
liquor fraction, leaving a dewatered cake of approximately 20%. The ammonium and
potassium will be partitioned into the liquor whilst the phosphorus will be largely retained in
the dewatered cake. (Fuchs et al., 2010).
Dewatering is often employed as a first step in digestate processing. The digestate fibre is a
semi-solid cake which is easier to store. This combined with reduced volume greatly
simplifies handling and reduces subsequent transport costs. Dewatering is also an
important treatment technique to improve the feasibility of land application. However as the
nutrient content will be lower than in the original whole digestate, nutrient content will need
to be considered in securing land-based outlets.
Dewatering digestate and reducing the water content also enables a number of other
technologies, such as energy recovery, to be economically employed (see Figure 3).
12
The liquor generated by the dewatering process will contain high levels of ammonium and
potassium. Subject to site specific requirements it is likely that this liquor will require a form
of treatment before it can be discharged to the public sewer. It may be possible to recycle a
fraction of the liquor for feed processing, where the liquor can be used to dilute the
feedstock to an acceptable solids concentration. However, the remainder of the liquor will
require treatment, involving the removal of nutrients from the liquor, by either recovery or
oxidation, to enable the liquor to be discharged.
As with thickening, polyelectrolyte can be added to digestate to improve coagulation and
increase the overall solids capture and operability of the dewatering system. Increasing
solids capture is very important to ensure the separated liquor contains a minimal quantity
of digestate solids to limit the biological treatment demand.
A typical sample of dewatered digestate is shown in Figure 4.
Figure 4. Dewatered Digestate
Purification (Ultra Filtration and Reverse Osmosis)
Physical purification uses a membrane as a physical barrier which acts as a molecular sieve
retaining contaminants, yet allowing water to permeate through. Subject to specific
membrane selection, the permeable membrane separates contaminants from the digestate,
at a molecular level; this produces a permeate stream potentially suitable for direct
discharge to watercourse, and a concentrate which can be applied as a fertiliser (Chiumenti
et al.).
Depending on the type of membrane selected, different contaminants will be retained on the
membranes. Ultra filtration (UF) membranes are capable of retaining soluble
macromolecules and larger particles; reverse osmosis (RO) membranes are capable of
retaining small molecules and ions. Due to the small pore size of the membranes (<5nm)
membranes can be susceptible to fouling and can be damaged by larger particles.
To prevent membrane fouling the process is typically used on the separated liquor rather
than the whole digestate. The concentrated stream retained by the membrane can be used
as a concentrated fertiliser (Fuchs et al., 2010).
13
4.2.2 Thermal Enhancement Techniques

Thermal techniques use thermal energy (heat) to either remove water from the digestate to
increase solids and nutrient concentrations or to recover energy from the digestate (such as
via combustion).
Thermal Drying
Thermal drying can be used to significantly reduce the remaining water within the digestate
to produce a product of up to 98% ds (SEVAR, 2012, Siemens, 2011). As the thermal
energy required to dry the digestate is directly proportional to the moisture content of the
feedstock, dewatering is typically employed as a pre-treatment technique prior to thermal
drying. The thermally dried product has a greatly reduced volume and, as it is a dry solid
material, can be easily handled, stored and transported. If required the dry product can be
pelletised to suit product use and aid both storage and transportation. The dried product has
a number of potential uses but is normally applied to land as an organic fertiliser or used as
fuel for energy recovery.
At the elevated temperatures utilised within the thermal drying process, ammonia will come
out of the solution and be contained within the evaporated fraction. This will need to be
condensed to form condensate, a high strength liquor which will require treatment prior to
discharge. It is possible for condensate treatment to be combined with treatment of
dewatering liquors.
In the case of solar drying no pre-treatment is required (Degremont, 2012, Thermo Systems, Veolia, 2006b), although it may be beneficial; also no condensate treatment is
required. Digestate is fed into a ventilated greenhouse where water is evaporated by
thermal energy derived from the sun. The digestate is continuously turned to ensure
consistent product quality. If an integrated system is developed, waste heat from a
combined heat and power (CHP) system can also be utilised to supplement solar energy via
underfloor hot water piping systems.
A typical sample of dried digestate is shown in Figure 5.
Figure 5. Dried Digestate
14
Digestate Concentration (Evaporation)
To concentrate digestate or increase dry solids content, evaporation can be applied.

Evaporation utilises thermal energy (heat) to release the moisture within the digestate and
increase both nutrient and solids concentration. Unlike the drying techniques discussed
above, evaporation aims to retain the nutrients and a proportion of the moisture contained
within the digestate. Evaporation is typically utilised for liquor or whole digestate treatment.
The final solids concentration will be dependent on the desired product, but concentrations
of up to 20% ds can be achieved. As with thermal drying, high temperatures will cause
ammonia to be released. This can be overcome by decreasing the pH of the digestate,
typically with acid dosing, prior to evaporation (HRS Heat Exchangers, 2010). This approach
allows the digestate liquor to be converted into a concentrated fertiliser.
Incineration
Incineration provides an alternative use of digestate to land-based application. Digestate is

combusted in order to achieve destruction of organic matter (Perry, 1997). If the moisture
content within the digestate is sufficiently low and the incinerator efficiency is high, the
process can become auto thermal (the process generates sufficient heat to allow
combustion to continue without the need for an external heat source or additional fuel) and
energy recovery can be achieved (Envirotherm GMBH, Veolia, 2006a, Tchobanoglous et al.,
2004). Autothermal operation will typically require a dry solids content of >40%. The
incineration process is best suited to digestates with a high calorific value or where landbased application is not financially viable or practical.
Ash from the process can be recovered and used as a construction material for roads or for
concrete production. Phosphorus can also be recovered from the ash by acid leaching.
Gasification
Within the gasification process, the oxygen supply is limited to enable partial combustion of
organic matter within the feed in order to produce a synthesis gas (syngas). Syngas is a
mixture of mainly carbon monoxide and hydrogen, which can be burnt to produce energy
(Perry, 1997). As with incineration, for the process to operate efficiently, the feed digestate
must have a low moisture content and ideally be in a dry pelletised form (i.e. the product of
a thermal drying process).
Gasification provides another alternative use of digestate to land-based application.
However the technology has yet to be fully developed for this application (Evans, 2008).
Wet Air Oxidation (WAO)
In the wet air oxidation (WAO) process organic material is oxidised within the liquid phase,
rather than in the gaseous phase, in contrast to other combustion processes. WAO is
achieved at elevated temperatures and high pressure to prevent evaporation.
These conditions also enable chemical oxidation of mineral components within the feedstock
(Chauzy et al., 2010).
The products from WAO are a mineral sludge, a liquid effluent and off gasses (Siemens,
2006).
15
Full scale plants are operational in Europe - the largest installation is Brussels WWTW which
treats digested sewage sludge from a population of 1.1 million.
Heat recovery is possible under the right conditions making the process auto thermal (Veolia
Water, 2010). The feed for the process is whole digestate, meaning that no pre-treatment
is necessary to reduce the moisture content of the feedstock compared with other thermal
destruction technologies. However, post-treatment of the by-products, mineral sludge and
liquor, may be required.
Pyrolysis
Pyrolysis processes heat the digestate in an oxygen free atmosphere breaking down
organics within the feedstock into char and syngas. The syngas typically contains mainly
hydrogen, methane and carbon monoxide (Perry, 1997).
For the pyrolysis process to operate efficiently the feed digestate must have a low moisture
content, and similar to gasification, often requires digestate in a dry pelletised form. The
pyrolysis process reduces the mass of the digestate by 70%, significantly reducing transport
costs. The char produced by the process can be used as a soil amendment or as a partial
replacement for peat in growing media production; both of these applications are
undertaken in accordance with appropriate regulatory controls (PYREG, 2011).
Pyrolysis process technology has been proven for this application however it is not yet well
established.
4.2.3 Biological Enhancement Techniques

Biological enhancement techniques use naturally occurring micro-organisms to convert
organic matter within the digestate in order to stabilise the digestate, reduce the organic
load or produce novel products such as biofuels.
Composting
The composting process aerobically breaks down organic matter in the digestate, resulting
in the conversion of ammonia to nitrate which is more stable, and a highly mobile nitrogen
source for plants (Tchobanoglous et al., 2004, Botheju, 2010). Temperatures within the
compost process can reach 70C or more due to the intensity of microbial activity, hence
pasteurisation can be achieved. However the ability to achieve pasteurisation will be
dependent on the composting process and the associated process control.
If physically suitable, the digestate can either be composted on its own or it must be cocomposted with a range of standard composting feedstocks, such as wood chip and green
waste. As an additive to standard composting the digestate provides a source of nitrogen,
phosphorus, magnesium and iron, as well as moisture. The standard composting feedstocks
provide a bulking agent, improve the carbon (C):nitrogen (N) ratio and consistency of the
final product (Evans, 2008). Co-composting is therefore beneficial for both waste streams.
Compost quality is and its subsequent use is regulated by PAS100. Provided the required
controls are in place, digestate from source segregated waste can be used as a compost
feedstock in compliance with PAS 100.
16
Reed beds
Digestate reed beds can be used to dewater, sanitise and mineralise the digestate over a
long period of time, typically 10-15 years (Nielsen and Willoughby, 2005). Whole digestate
is fed into a sealed basin containing a bed of reeds. The digestate is treated by bacteria
within the root systems of the reeds and evapotranspiration drives off water, typically
dewatering the digestate to 30-40% dry solids.
Liquor collected from the basins can be recycled as process water or used for irrigation.
At the end of the treatment period the beds are dug out and the digestate applied to land
(ARM Biosolids, 2012, Blumberg, 2012). The area required for treatment is dependent on
the type of digestate but typical loading rates are between 20 and 60 kg dry solids/m/yr.
A typical view of digestate reed beds is shown in Figure 6.
Figure 6. Digestate Reed Bed
Biological oxidation can be used to reduce the loading of biological oxygen demand (BOD)
and ammonia in the digestate. The process is most commonly used to treat the digestate
liquor prior to discharge either to sewer or watercourse, however it can also be used as a
pre-treatment stage or used to treat the whole digestate (wet composting). Typically the
digestate is aerated in the presence of bacteria which oxidise the BOD and ammonia. The
treatment of liquors in this manner is well proven but can have high operating costs.
The process produces a biological sludge as a by-product which can be returned as a
feedstock to the digester.
Examples of these processes include membrane bioreactors (MBR), sequencing batch
reactors (SBR), moving bed bioreactors (MBBR) and the SHARON process.
17
Biofuel Production
Biomass within the digestate has the potential to be utilised as a feedstock for biofuel
production. Several possible techniques are currently being developed.
Digestate liquor can be used as a feedstock for the production of algae which in turn can be
converted to biofuel (Iyovo, 2010, Uttleu). Water separated from the algae can be used as
process water or for irrigation; waste algal biomass can be used as a digestion feedstock.
This process is currently operational at pilot scale in the Netherlands (Algae Food & Fuel,
2009).
A typical view of algal bioreactors is shown in Figure 7.
Figure 7. Bioreactors for the production of Algae from digestate liquors
The digestate fibre can also be converted into biofuel by a process of hydrolysis and
biological fermentation (Yue, 2010). Ethanol yields from the process are reported to be
comparable to some traditional energy crops (Teater, 2011). This process is only currently
operational at laboratory scale.
It has also been shown that freshwater and nutrients used for bio-ethanol production from
traditional energy crops can be replaced with dewatered liquor (Gao, 2010). Using digestate
liquor in this manner has been shown to significantly increase ethanol yields.
18
Microbial Fuel Cell
Microbial fuel cells (MFC) are a novel application of fuel cells that has potential to produce
bioelectricity from the biological oxidation of organic matter. The process utilizes the ability
of particular microorganisms to transfer electrons directly to an anode during respiration
(Aelterman, 2006). The reactions take place under anaerobic conditions. This process is
only currently operational at laboratory and pilot scales. Laboratory trials have shown the
process to be capable of removing 3.99kg COD/md (Peixoto, 2012).
A schematic of a microbial fuel cell is shown in Figure 8.
Figure 8. Schematic of a typical microbial fuel cell.
(Zeng et al., 2010)
19
4.2.4 Chemical Enhancement Techniques

Chemical enhancement techniques utilise chemical reactions and equilibria to recover
nutrients from the digestate or modify its properties.
Struvite Precipitation
Struvite is the name commonly used for the chemical compound magnesium ammonium
phosphate which can be used as an inorganic fertiliser (Evans, 2009). Under the correct
conditions struvite can be precipitated, allowing ammonium and phosphorus to be extracted
from the digestate. pH adjustment and magnesium ion addition are usually required
(Nawa). Struvite is recovered as a solid material, well suited for export for use as either a
fertiliser or as a base feedstock for fertiliser production. Phosphorus is a finite global
resource and as a consequence struvite recovery is likely to become more important in the
future (Driver, 1998).
This process will not normally remove all of the ammonium from the digestate, as there are
insufficient quantities of phosphorus present in the digestate.
Figure 9. Struvite products. Precipitated struvite crystals (left) and granular struvite pellets
produced in a fluidised bed reactor (right)
Ammonia Recovery
Ammonia, in the form of ammonium, can be recovered from the digestate for use as a
concentrated fertiliser or a chemical feedstock. A number of different techniques are
commercially available (Maurer et al., 2001). The efficiency of all of these techniques can
be improved by increasing the temperature and the pH of the digestate (Gutin, 2011). If
waste heat from a combined heat and power (CHP) system is used to increase the
temperature of the process, financial support from the Renewable Heat Incentive (RHI) can
potentially be claimed.
20
Ammonia can be stripped from the digestate by contacting with air or steam. Ammonium
can then be recovered by scrubbing the stripping gas in a second column (Colsen
International, ngeles De la Rubia et al., 2010). Depending on the scrubbing solution used,
ammonium can be recovered in a number of forms including ammonium sulphate and
ammonium nitrate, both of which have value as inorganic fertilisers (Evans, 2009).
Membrane contactors can also be used to recover the ammonia (Liqui-Cel, 2009). Digestate
and sulphuric acid are fed, counter currently, on opposite sides of a microporous
hydrophobic membrane. Gaseous ammonia is removed across the air filled pores of the
membrane where it reacts with the sulphuric acid to produce ammonium sulphate.
Figure 10. Schematic of a membrane contactor (Liqui-Cel, 2009).
Ion exchange processes recover ammonium by adsorption. Digestate is fed into a packed
bed of adsorbent where the ammonium is selectively adsorbed by ion exchange. Once
saturated the column is taken off-line and regenerated, recovering the ammonium. The
form of the recovered ammonium is dependent on the regenerating solution used (Maurer
et al., 2001). A wide range of adsorbents are available including zeolites, clays and resins
(Cooney et al., 1999).
21
Acidification
Sulphuric or other acids can be added to the whole digestate prior to land application to
decrease the pH and shift the ammonium/ammonia equilibrium towards ammonium. This
reduces nitrogen loss from the digestate once applied to land. Careful consideration must
be given to the soil type of the land bank as application of acidic digestate will not always be
acceptable (Ministry of Economic Affairs Agriculture and Innovation of the Netherlands,
2010, Frandsen et al., 2011).
Alkaline stabilisation raises the pH of the digestate in order to achieve pathogen kill,
neutralise odours (typically hydrogen sulphide) and prevent the digestate from becoming
septic. However increasing the pH can cause ammonia to be released causing odour issues.
Lime is typically used for the alkali stabilisation (Tchobanoglous et al., 2004). This
technique is commonly used to treat dewatered sewage sludges.
22
5.0 Digestate Enhancement Systems

5.1
Digestate Treatment Systems
The number of enhancement techniques employed, and the complexity of the treatment
system, will be highly dependent on the available land-based outlets, potential markets and
the desired digestate products. Treatment systems are highly site specific and no single
system will be optimal for all sites.
For small sites, with readily available local agricultural land, it may be possible to spread the
whole digestate to land, providing it is compliant with the relevant legislation (or end of
waste status via PAS110 and the ADQP) and satisfies the seasonal spreading requirements.
Under these conditions there may be no argument for any digestate enhancement.
However, as the distance to the land-based outlet increases further enhancement may be
required, such as dewatering or drying to optimise storage, handling and reduce transport
costs. Investing in such enhancement technologies must also consider the implication of
associated by-products as significant volumes of liquor will be produced, either as
filtrate/centrate or condensate which will require treatment prior to discharge to sewer or
watercourse.
Where no land-based outlet is available thermal conversion may be the only economic
option, potentially requiring dewatering, drying and associated liquor treatment.
In recent years there has been increased focus on creating marketable products from
digestate. Possible methods for achieving this include nutrient recovery and the addition of
nutrients to create a more balanced fertiliser. Two possible techniques for enhancement are
highlighted in the examples included in Section 5.4 and 5.6. The Scottish and Southern
Energy (SSE) energy from waste plant at Barkip utilises HRS scraped surface heat
exchangers to recover nutrients from the digestate. The IVAR IKS biofertiliser plant
produces an organic fertiliser (MINORGA) from food waste and sewage sludge in Norway
following digestion and thermal drying.
Technologies are also emerging to create novel products from digestate such as biofuels.
These technologies are still at an early stage of development but have the potential to
provide interesting possibilities in the future.
The following diagrams provide examples of an integrated treatment system designed to
recover nutrients from digestate, recycle dewatered digestate fibre products to land and
convert digestate fibre to other product forms. These systems will not be applicable to all
plants but the diagrams aim to highlight how technologies can be combined and the need to
integrate the systems to create a wide range of digestate products.
A schematic of a potential integrated digestate enhancement system for the liquor stream is
shown in Figure 11 and the fibre stream is shown in Figure 12.
23
Figure 11. Flow Diagram of Potential Digestate Enhancement System (liquor)

Heat
Biogas
CHP
Whole
Digestate
Feed
Digester
Power
Dewatering
Digestate
Liquor
Sludge
Air
Membrane Bio
Reactor
Magnesium Hydroxide
Sulphuric Acid
Struvite
Precipitation
Magnesium
Ammonium
Phosphate
(Struvite)
Ammonia
Stripping
Ammonium
sulphate
Water reuse
Effluent
Process Stages
Potential products or resource recoveries
24
Figure 12. Flow Diagram of Potential Digestate Enhancement Systems (Fibre)

Heat
Biogas
Feed
Digester
CHP
Whole
Digestate
Power
Liquor to
treatment
(Figure 11)
Dewatering
Digestate Fibre
Lime
Thermal
Drying
Alkaline
Stabilisation
Composting
Boiler
Steam
Turbine
Heat
Incineration
Gasification
Ash recycling / disposal
Power
Pyrolysis
Land
Based
Outlets
Biochar
recycling
Syngas to
CHP/ Gas
turbine
Power
Process Stages
Potential products or resource recoveries
Enhancement
Option gate
25
5.2
Digestate Enhancement Systems
The following describes the combination of treatment technologies/techniques that have the
potential to generate a number of complementary digestate products see Figure 12.
Digestate is first dewatered to separate the liquid and solid fractions. The dewatered fibre
can then be applied directly to land or utilised for energy recovery.
The first stage of the liquor treatment process presented in Figure 11 is aerobic reduction of
chemical oxygen demand (COD) within a membrane bioreactor (MBR). The process is
configured such that no ammonia is oxidised.
Sludge generated by the MBR is recycled back to the digester. Effluent from the MBR is
dosed with magnesium hydroxide to increase the pH and magnesium ion concentration,
enabling struvite precipitation. Heat from the CHP is also used to improve struvite removal
and the use of heat in this manner may be eligible for financial support from the Renewable
Heat Incentive (RHI).
Struvite is precipitated and extracted for use as an organic fertiliser. As equimolar amounts
of ammonia and phosphate are used in struvite production, and digestate is relatively rich in
ammonia, there remain significant quantities of ammonium within the digestate liquor. In
order to recover this ammonium the liquor is fed into an ammonia stripper; as the pH and
temperature of the digestate have already been increased the conditions are more suitable
for the stripping process. In addition, the risk of fouling within the ammonia stripping
column is greatly reduced as the COD has already been removed by the MBR.
The stripping process recovers the ammonia as ammonium sulphate. Sulphuric acid and
heat are used within the process; again this application of heat from the CHP may also be
eligible for financial support from the Renewable Heat Incentive (RHI).
The treated liquor from the process can be reused as process water, used for irrigation or
discharged to sewer. Alternatively, an additional treatment stage can be added in the form
of reverse osmosis (RO) to produce higher quality process water or enable direct discharge
to a watercourse.
Combining the individual process units into the treatment system above provides an
integrated and holistic treatment process capable of producing both solid and liquid fertiliser
products from digestate. Waste heat from the CHP may also be utilised in order to generate
additional income from the RHI and the effluent is suitable for reuse within the process.
However this system incorporates several complex subsystems that require careful
integration and operation.
26
5.3
Current Barriers to Enhancement Systems
The use of digestate enhancement technologies/techniques faces a number of barriers in

the UK, preventing their widespread adoption. The most significant barrier is the current
cost of installation, as well as the operational costs associated with the technologies. This
barrier is directly linked to the cost of alternative disposal arrangements such as landfill or
energy recovery facilities. However, the relatively low value of digestate products and the
associated cost of developing outlets or markets for these products is also a significant
barrier.
It is imperative that the installation of a single digestate enhancement system does not
frustrate, or in the extreme negate, subsequent treatment process additions. However the
cost of installing a suite of totally integrated enhancement systems, as described in Section
5.1 and 5.2, presents a significant financial challenge that the sector is unlikely to be able to
fund at this stage.
A key step to overcoming these barriers is to raise awareness of the waste sector to
enhancement technologies and techniques, to reduce costs and to emphasise the financial
benefits of implementing enhancement systems to secure potential income from digestate.
Whilst this research exercise has identified a range of potential techniques and methods for
treating and enhancing digestates in the UK these options will not be adopted until the
business models exist that ensure that the financial investment is worthwhile. There is a
need to raise awareness of potential improvements to digestates and ensure that the
industry is aware that there may be advantages in developing flexible sites where changes
can be adopted as new technologies become available.
27
5.4
Technology Example: Barkip Biogas Facility
5.4.1 Background
HRS Heat Exchangers have been contracted by Scottish and Southern Energy (SSE) to install
their Unicus scraped surface evaporators for digestate liquor treatment at the Barkip
anaerobic digestion plant.
Barkip biogas facility is the largest anaerobic digestion plant in Scotland. The site, located in
a former landfill site in North Ayrshire, will process up to 75,000 tonnes of waste food,
manure and organic effluent sludges. The plant is the first of its kind to incorporate the heat
exchanger technology developed by HRS. Scraped surface heat exchangers use heat
generated from the process to concentrate the liquid fraction of the digestate into a
nutrient-rich fertiliser.
Scraped surface evaporator plants are designed to overcome fouling issues associated with
the evaporation of organic digestate. The interior surface of the heat exchanger tubes is
constantly cleaned by internal scrapers to reduce fouling and increase heat transfer
efficiency. Although this is the first time the technology will be utilised for digestate
processing, the heat exchangers are well proven for other applications, most relevant being
the concentration of pig manures.
Key Facts
Technology Supplier: Xergi, HRS Heat Exchangers.

Client: Zebec Energy on behalf of Scottish and Southern
Electric.
Throughput: 75,000 tpa.
Feedstock: Food waste, animal manure, organic sludges.
Technologies employed: Two stage Thermophilic Anaerobic
Digestion, centrifuge, scraped surface heat exchangers.
Project stage: Operational, PAS110 certified.
Capital cost: 1.3 million (evaporation plant only).
Electrical generation: 2.5MW.
28
Figure 13. Scraped Surface Heat Exchanger Cut Away
5.4.2 Process Description

Digestate from the process is fed into a centrifuge in order to separate the liquor and fibre
fractions. The digestate liquor is then pre-treated with acid prior to evaporation within the
scraped surface heat exchangers to prevent ammonia loss within the evaporator. The
volume of acid dosed is dependent on the digestate and the desired retention. Within the
evaporator the liquor is concentrated to approximately 20% Dry Solids (DS). The evaporator
operates under vacuum at temperatures between 50C and 70C. Heat required for the
process is provided by the combined heat and power plant (CHP). This application of heat
may be eligible for financial support under the Renewable Heat Incentive (RHI).
The evaporators at Barkip are capable of treating 10,800 kg/h of digestate liquor and
producing 1,565 kg/h of concentrate.
The concentrate can then be mixed with the separated digestate fibre to produce a nutrient
rich solid fertiliser for export. Distilled condensate for the process is recycled as process
water with any excess discharged to public sewer.
For the Barkip application the heat exchanger tubes have been constructed from Duplex
steel due to the high chloride content within the feedstock.
Key Benefits
Nitrogen is retained within the digestate, improving fertiliser

potential.
Concentrated fertiliser reduces transport costs.
Additional income from Renewable Heat Incentive (RHI).
High levels of N/P/K retained within the digestate.
29
5.5
Technology Example: Lee Moor EFW
5.5.1 Background
British engineering company AeroThermal Group Ltd has been granted planning permission
to develop a sustainable waste and resource treatment facility at the site of Imerys Minerals
Ltd at Lee Moor in South Devon.
AeroThermals autoclave is a pressure vessel that steam treats its contents at a constant
temperature and pressure, serving to sterilise, clean, and break-down organic and lignin
structures and reduce waste volume by approximately 60%.
The Lee Moor facility will utilise an autoclave to pre-treat the digester feedstock. Pretreatment by autoclave pasteurises, cleans and breaks down organic matter and lignin
structures within the feedstock. This enables contaminants within the feedstock to be
removed more effectively, greatly enhancing biogas generation and the quality of the
digestate.
Once operational the site will divert 58,000 tonnes of waste from landfill every year and
generate 26 gigawatts of renewable electricity.
Recyclable materials will also be recovered from the waste stream and the stable digestate,
a by-product of the Advanced Anaerobic Digestion (AAD) process, will be used to help
restore parts of the adjoining Lee Moor China Clay workings.
Figure 14. Autoclave Pressure Vessel
30
Key Facts
Technology Supplier: AeroThermal Group Ltd.

Throughput: 58,000 tpa.
Feedstock: Municipal waste.
Technologies employed: Autoclave, Anaerobic Digestion,
centrifuge dewatering.
Project stage: Pre construction.
Capital cost: 15 million.
Electricity generation: 3MW.

Feed material is loaded into a pair of autoclaves in weighed 10 tonne batches. The
autoclaves are fed up to 10 times per day, each at a maximum of 10 tonnes per batch via a
system of conveyors from the weighing hopper. The autoclaves operate in an alternating
batch mode: residual steam is recycled from the duty unit that has completed its processing
to the autoclave that has been loaded and is waiting to start the cycle. This procedure not
only improves the steam utilisation efficiency but also significantly reduces the release of
steam to atmosphere.
Once loaded the duty autoclave is rotated. Flights within the autoclave lift the feed material
towards the top of the chamber where it then falls back to the bottom of the vessel to
create a continuous mixed flow. Steam is then injected until the autoclave internal pressure
of 5.2 bar and a temperature of 160C is achieved. These conditions are maintained for the
duration of the treatment process. After treatment the autoclave is returned to atmospheric
conditions, the bottom door is opened and the rotation of the vessel is reversed. This allows
the flights within the vessel to act as a screw conveyor and force processed material out.
After processing, inorganic material and contaminants can be easily removed via mechanical
separation providing a clean, pasteurised, organic rich feedstock for anaerobic digestion.
Digestate from the anaerobic digestion process is dewatered by a conventional centrifuge.
The digestate fibre is used for land restoration. Liquors from the process are partially treated
by dissolved air filtration before being recycled for feed preparation. Excess waste water
which cannot be recycled will be treated by a membrane bioreactor (MBR) to enable direct
discharge to an adjacent watercourse.
31
Key Benefits
5.6
Pasteurisation.
Waste resource recovery.
Waste minimisation.
Digestate recycling.
Technology Example: MINORGA Bio fertiliser, Norway
5.6.1 Background
Research has been undertaken in Norway at Stavanger Regional Wastewater Treatment
Plant (RWTP) into developing a digestate-based organic fertiliser with a consistency, particle
size and nutrient composition comparable to mineral fertilisers. Extensive field and product
trials have concluded with an organic product called MINORGA.
During the period 2007-11 extensive trials and field experiments were undertaken into the
development of an organic fertiliser based on thermally dried digestate. The research has
been conducted at Stavanger Regional Wastewater Treatment Plant by the plant operator
IVAR IKS in conjunction with the HST Valuable Waste Company.
The concept of the fertiliser product is based on supplementing the phosphorous within the
thermally dried digestate produced at Stavanger with the addition of nitrogen and
potassium. The resulting product, called MINORGA, is a granular organic fertiliser with an
N-P-K ratio of 10-2-5.
Figure 15. MINORGA Pellets
32
The product is considered more environmentally friendly than similar mineral fertilisers
leading to less run-off and a prolonged fertilising effect. In that context, the product also
offers a better balanced phosphorus supply (Tornes et al, 2010).
Agronomic trials showed no significant differences in nutrient uptake between MINORGA
and commercially available mineral fertilisers. Spreading tests performed by a conventional
farm spreader showed distribution patterns very similar to that of commercially available
mineral fertilisers.
Key Facts
Technology Supplier: Graintec, Denmark.

Throughput: 10,000 tpa of MINORGA.
Feedstock: Sewage sludge and organic wastes including
domestic food waste and catering waste from hotels.
Technologies employed: Mesophilic anaerobic digestion,
thermal drying, nutrient addition, palletisation.
Project stage: Contract established.
Capital cost: NOK 40M (4.3M).

The development to date has been based on the manufacture of an organic fertiliser product
from a mixture of digestate and mineral compounds such as urea and potassium chloride.
The facility to produce the fertiliser product will be integrated into the existing sewage
sludge treatment process at Stavanger (RWTP).
The fertiliser facility comprises of storage silos for the addition of urea, potassium chloride,
meat bone meal or other mineral salts/high quality organic by-products, a dosage and
mixing system, pelletising plant and a big bag loading and packaging system. Thermally
dried digestate produced by the Stavanger RWTP will be directed to a batch dosing and
mixing system before the mixture is transported to the pelletising plant. The pellets will pass
through an air cooler followed by a sieve to ensure uniform product quality before the
product is stored in a product silo. Undersized pellets will be recycled back to the pelletising
system.
The final product will be packed in big bags containing 600 kg of MINORGA, the registered
name of the organic fertiliser. Pasteurisation of the digestate is achieved within the thermal
drying plant; the presence of organic pollutants has been systematically investigated in
surveillance studies and found to be either absent or at negligible and acceptably low levels.
The process flow diagram for the system is schematically presented below.
33
Figure 16. MINORGA Process Schematic
The total investment costs are approximately NOK 40 million. To reduce operating costs
IVAR IKS continue to investigate alternative sources to urea and potassium chloride
including nitrogen and potassium recovery from dewatering liquors generated at the
regional wastewater treatment plant.
Key Benefits
Pasteurisation.
Waste minimisation.
Waste resource recovery.
Low transport volume of dried and pelletised product.
Production of a marketable organic fertiliser.
34
6.0 European Perspective

6.1
Background
Landfill rates for municipal waste have decreased steadily from 62% in 1995 to 37% in 2010
in the EU-27, with 38 % of municipal waste recycled or composted/digested in 2010
compared to 17 % in 1995. EU and national policies targeting municipal waste have been
important drivers of this development (EEA 2012). The biomass categories used as
substrates (feedstock) for anaerobic digestion in European biogas production are animal
manures and slurries; agricultural residues and by-products; digestible organic wastes from
food and agri industries; the organic fraction of municipal and catering wastes; sewage
sludge; and dedicated energy crops such as maize, miscanthus, sorghum, and clover
particularly in Austria and Germany (Al Seadi et al. 2008).
Digestate composition and qualities are a function of input materials and process approach,
hence enhancement technologies need to be robust and capable of dealing with a range of
inputs in order to achieve significant market penetration.
6.2
Survey Data
A 2011 survey of AD facilities across Europe (including the UK) identified several thousand
specific facilities (excluding waste water treatment plants). Typically these are co digestion
facilities accepting a variety of different inputs, constructed by a variety of different
technology providers (Voss 2012).
The survey indicated that EU countries can be grouped based on the number of AD facilities
identified as follows:
>>1,000 facilities: Germany.

>>100 facilities: Austria, Belgium and Luxembourg combined, the Netherlands.
~ 100 facilities: Denmark, Italy, Czech and Slovak republics combined, UK.
< 100 facilities: Finland, France, Hungary, Poland, Portugal, Spain, Sweden.
~ 10 facilities: Bulgaria, Greece, Latvia, Romania, Slovenia.
The level of detail is variable but indicates that the majority of these digester facilities accept
biomass crops in Austria and Germany; whereas facilities in the UK, Finland, France,
Sweden, the Netherlands focus on waste derived from agricultural or urban sources. The
number of digestion facilities reported in the survey is higher than a study quoted by the
Technical Report for End-of-Waste Criteria (EC JRC 2011), which identified 166 anaerobic
digestion facilities for biowaste and municipal solid waste across 15 EU countries. The
difference between the total number of AD facilities is explained by the fact the End of
Waste report did not include farm based systems.
Typically solid/liquid separation is a precursor to any further product enhancement
treatment, which is very similar to digestate management practice for wastewater treatment
plants.
35
6.3
Transport Optimisation
There is growing interest in the development of more readily transportable products from
digestion. Many European facilities operate solid/liquid separation, to reduce transport costs
for the solids fraction, to facilitate storage (e.g. over the closed season) and to increase the
potential radius of digestate use. Some facilities use evaporation to concentrate liquid
fractions using waste heat, again to increase the effective radius of use. This is of particular
interest in Germany where subsidies for electricity production provide the incentive for AD
facilities, where there is no immediate CHP opportunity (Voss 2012).
Hybrid systems utilising both AD and composting systems are also in use. Composting of
digestate with additional feedstocks, is undertaken to reduce water content and overcome
stability and odour problems; in addition hybrid systems have been found to improve
materials handling and improve product value (e.g. Swedish Gas Association 2008). The IEA
Bioenergy Task 37 group recommend that the solids fraction should be stored without
disturbance, or even composted, in order to avoid methane emission (Lukehurst et al.
2010).
The Netherlands view the development of solutions to digestate use as important in
enabling the expansion of AD as a biogas resource, and has a range of enhancement
approaches under consideration, including the extraction of substitute fertilisers from
digestates (New Gas Platform, Green Gas work group 2010). The availability of
opportunities for digestate use is a key factor in selecting the location of AD facilities in the
Netherlands (New Gas Platform, Green Gas Work Group 2010, Energy Transition, New Gas
Platform 2011).
Example configurations include the following (IEA Bioenergy Task 37 2012, Swedish Gas
Association 2008):
Boden plant, Sweden: operating since 2003: thermophilic (55oC) co-digestion of sewage
sludge (960 tonnes dry solids per year) and household food wastes (1,200 tonnes per
year) producing biogas for transport vehicle use and waste heat which is used for district
heating. 1,600 tonnes of digestate is produced per year, some of which is used to
produce a soil conditioner. Digestate is de-watered by a centrifuge plant to
approximately 30% dry solids. The dewatered digestate is stored in silos and transported
by truck.
Helsingborg plant, Sweden: operating since 1997, feedstock: household food wastes,
food industry wastes and pig manure, approximately 45,000 tonnes per year. Digestate
is pumped to farm users via a 10 km pipeline (capacity 20,000 tonnes per year).
Karpalund plant, Sweden: operating since 1996, feedstock: household food wastes,
manure, slaughterhouse waste, approximately 60,000 tonnes per year. Digestate is
sieved to remove debris such as plastics and then dewatered before storage and use.
Inwil plant, Switzerland, operating since 2008, based on a thermophilic plug flow
digester treating source separated collection of municipal solid waste and two mesophilic
continuously stirred tank reactor digesters treating mainly pig manure. Industrial waste
is also accepted. The total waste volume treated is approximately 60,000 tonnes per
36
year. After dewatering the solid output (13,000 tonnes per annum) is matured under
aerobic conditions, and the liquid output is treated by ultrafiltration and reverse osmosis
to obtain a concentrated liquid fertiliser (10,000 tonnes per annum) and clean water.
The liquid fertiliser is transported to farmers. (Similar liquid fraction treatment
configurations have been tested at pilot scale in Sweden - Svenskt Gastekniskt Center
2010).
6.4
Summary of EU Waste Sector
There is widespread interest in the development of enhanced products from digestates. The
work of the International Energy Authority (IEA Bioenergy Task 37) indicates research
interests for processing digestate into value added products are present in Austria,
Denmark, Finland, France, Germany, Netherlands, Norway and Sweden. The exact nature
of the research being undertaken is not always specified in the IEA documents but is largely
related to chemical, physical and thermal processes for solid liquid separation, and
downstream conversion of solids or liquids into fertiliser products such as struvite.
Research in Germany includes an investigation of the utilisation of CO2 and nutrients from
digestate for micro-algae production and hydrothermal gasification of digestate for
additional CO2 and CH4 production (IEA 2010, 2011, 2012).
Over a number of years research has also been supported under the EC Framework
Research Programmes, including several hundred projects related to anaerobic digestion
through the Cooperation, Ideas, People and Capacities sub-programmes. These can be
viewed using the CORDIS database at http://cordis.europa.eu/home_en.html. A small
proportion of these projects are related to digestate enhancement. These include
investigations of: struvite recovery, sulphur recovery (for high sulphur content wastes),
ammonia stripping and recovery, ethanol production, algal production, and thermal
conversion of digestate to energy.
The EU funded Eco-Innovation programme supports the market replication of new
environmental products and services across a range of categories, including projects related
to anaerobic digestate products. Eco-Innovation project information is posted on
http://eaci-projects.eu/eco/page/Page.jsp. Projects agreed for 2012 will be listed on the site.
Several AD facility development projects are also being funded under the Intelligent Energy
Europe Programme (http://ec.europa.eu/intelligentenergy).
37
7.0 Summary
The technologies and enhancement techniques identified within this study represent a wide
range of potential options for digestate enhancement which could support the development
of digestate products. This wide range indicates that no one technology is applicable for all
applications and a range of solutions will be required to support the planned increase in
anaerobic digestion facilities in the UK with the consequential increase in volumes of
digestate generated.
The majority of digestate currently produced in the UK is recycled to land as either whole
digestate or dewatered fibre. Digestate liquor is commonly treated by biological oxidation,
particularly in the waste water industry. However, there is increased interest in creating
improved fertiliser products from digestate, in order to increase its value, secure outlets and
potentially generate an additional revenue stream for the plant. A number of the
technologies identified in this report have proven potential to create these products.
Currently there are a large range of options available for digestate treatment and recovery.
However the most significant barrier in the UK is the current cost of installation and the
operational costs associated with the technologies. Ultimately the type of treatment
employed to provide the most economic recovery route will depend on a number of factors,
including:
level of enhancement desired / required;

market for digestate products;
plant throughput;
available footprint;
feedstock;
availability of land-based markets;
distance to land-based markets; and
soil type of receiving land.
UK markets for waste derived digestates are immature. There is existing competition in land
based markets, not least with conventional inorganic fertilisers. However, in the future as
natural phosphorous resources decrease and the cost of inorganic fertilisers increase,
farmers will look to find alternative and potentially cheaper sources of nutrients for their
crops.
It is anticipated that the practical demand for these products will increase as the financial
and commercial value increases. The key challenge in the short term will be to manage the
increase in digestate and secure outlets.
From the EU waste sector perspective, there are clearly similar challenges and goals to the
UK waste sector. A key difference is the cost of waste treatment and disposal which is
significantly higher in the EU than in the UK. This economic differential has driven certain
EU states to develop anaerobic digestion facilities with EU funded support for the
development of digestate products and markets. This development work has been underway
over the last ten years. Research and development continues with a focus on the
development of enhanced products from digestates, most notably the International Energy
Authority (IEA Bioenergy Task 37) and the Eco-Innovation project.
38
In conclusion, a wide range of technologies and techniques are available to create novel
digestate products - such as concentrated nutrient streams for the production of
standardised fertiliser products. However, operational experience of these technologies in
the UK is currently limited and in many cases, direct land application is likely to remain the
most economic option. Operational experiences should be sought from the EU, where
systems have been installed and digestate products created to satisfy outlet demand.
As the market for digestate products and competition for land-based markets increases, it is
anticipated that these technologies will become more important in the near future.
39
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42
Appendix 1
Organisation Contact List
Enhancement and treatment of digestates from anaerobic digestion A1
Organisation
Type
Website
ADBA
(Anaerobic Digestion and
Biogas Association)
Organics Recycling
(Association for Organics
Recycling)
Association
http://www.adbiogas.co.uk/
Association
http://www.organics-recycling.org.uk/
ESA UK
(Environmental Services
Association)
CIWM
(Chartered Institution of
Wastes Management)
UK CPI
(Centre for Process
Innovation)
Water UK
Aqua Enviro
Association
http://www.esauk.org/
Association
http://www.ciwm.co.uk/CIWM/CIWMHome.aspx
Association
http://www.uk-cpi.com/
Association
Consultancy
http://www.water.org.uk/
http://www.aquaenviro.co.uk/
Association
http://www.r-e-a.net/
Consultancy
Joint Venture:
Waste
Management
Company and
Consultancy
Technology
Supplier
Association
Technology
Supplier
Technology
Supplier
University
University
University
University
Consultant
Business &
Service
Laboratory
Stakeholder
Association
RTD &
Consulting
http://www.adas.co.uk/
REA
(Renewable Energy
Association)
ADAS
AWS Burdens Environmental
Ltd
HRS Heat Exchangers Ltd

International Energy Agency
Black and Veatch
Pyreg UK
Leibniz Universitt Hannover
University of Reading
University of Brighton
University of Minho
VE efficiency solution GmbH
Biobench B.V.
Environmental Institute
Cre-Composting Association
of Ireland Teo
Simbiente
http://www.hrsheatexchangers.com/en/default.aspx
http://www.iea.org/
http://bv.com/
http://www.pyreg.com/English.html
www.isah.uni.hannover.de
www.reading.ac.uk/ges/
http://www.brighton.ac.uk
http://bio4e.deb.uminho.pt
www.ve-gmbh.de
www.biobench.com
www.ei.sk
www.cre.ie
www. simbiente.com
Organisation
Type
C-CURE
University of Debrecen
ACR+
Austrian Biomass Association
COPA-COGECA,
Technology
Supplier
University
Association
Association
Association
ORBIT / European
Composting Network
ISWA
(international solid waste
association)
WSSTP [sewage] Sludge
Group
Website
Association
www.ccuresolutions.com
http://portal.agr.unideb.hu
(www.acrplus.org)
http://www.biomasseverband.at/
www.copacogeca.be/Main.aspx?page=HomePage&lang=en
http://www.compostnetwork.info/
Association
http://www.iswa.org/
The Water
Supply and
Sanitation
Technology
Platform
http://www.wsstp.eu/site/online/home
Appendix 2
Technical Data Sheets
APPENDIX 2 - Technical Data Sheets

This appendix includes the technical data sheets for the digestate enhancement technologies
discussed in Section 4. The aim of these technical data sheets is to provide a brief
description of the operating principle of the technology/technique, operating conditions and
associated benefits, challenges and opportunities.
The criteria within the data sheets are all scored using the same system of between 1 and 5
stars, where:
1 star represents a low value or poor performance against the criteria, and
5 stars represents a high value or excellent performance.
The exception to the above is the stage of development which is ranked out of 6, as
classified below.
Stage of Development
Established
Maturing
Emerging
Near commercial
Pilot
Research
Rating
Note that the stage of development refers to the technologies application to digestate.
For example, a technology that is established in another field but is emerging as a digestate
treatment will be scored as an emerging technology.
Technical Data Sheets
Page
Pre and in-digestion Enhancement

Thermal Hydrolysis
Autoclave Systems
Enzymic Liquefaction
In vessel Grit removal
In-vessel scum removal
A4
A6
A8
A10
A12
Physical Enhancement
Thickening (Belt)
Thickening (Centrifuge)
Dewatering (Belt)
Dewatering (Centrifuge)
Dewatering (Hydrocell)
Dewatering (Bucher press)
Dewatering (Electrokinetics)
Purification (Ultrafiltration and Reverse Osmosis)
A14
A16
A18
A20
A22
A24
A26
A28
Thermal Enhancement
Drying (Rotary Drying)
Drying (Belt drier)
Drying (J-Vap)
Drying (Solar)
Evaporation (scraped surface heat exchangers)
Conversion (Incineration)
Conversion (Gasification)
Conversion (Wet air oxidation)
Conversion (Pyrolysis)
A30
A32
A34
A36
A38
A40
A42
A44
A46
Biological Enhancement
Composting
Reed Beds
Biofuel Production (Algae)
Biofuel Production (hydrolysis of fibre to Bioethanol)
Microbial Fuel Cell
A48
A50
A52
A54
A56
A58
Chemical enhancement
Struvite precipitation
Ammonia recovery (Stripping + Scrubbing)
Ammonia recovery (Membrane Contactor)
Ammonia recovery (Ion Exchange)
A60
A62
A64
A66
A69
Process
Thermal Hydrolysis
Process Type
Objectives
Thermal (pre-treatment)
To break down the cell structure of organic matter to improve biogas
production and ease of dewatering. Pasteurisation is also achieved.
Process Flow
Diagram
Feed
Process
Description
Heat Recovery
Steam
Reactor
Buffer
Digester
Within thermal hydrolysis processes the feed is heated and pressurised

by steam within a reaction tank before the tank is rapidly depressurised
(flashed). The process results in the breakdown of cell structures
within the biomass, improving digestibility and digestate quality. When
dewatered a higher dry solids cake can be obtained, making the
material easier to store and transport. The high temperature of the
process (150 180C) pasteurises the biomass.
Reactors operate in batches, therefore several are usually combined to
provide continuous treatment. Energy recovery between the reactors
optimises energy efficiency.
If the anaerobic digestion process utilises a CHP plant, heat from the
CHP can be used to provide steam for the thermal hydrolysis process.
Several plants are operational in the UK treating sewage sludge
generated by waste water treatment works. Two full scale plants,
treating food waste, are also operational in Norway, with two more at
the construction / planning stage.
Benefits
Pasteurisation.
Increase biogas yield.
Increased dry solids if dewatered.
Improved solids destruction, reducing
digestate mass.
Challenges
High temperature and pressure.
High energy requirement.
Operating Conditions
Feed solids %ds
<18%
pH
N/A
Temperature C
150 - 180
Pressure
5-10 bar
Throughput (m/d)
Chemical Consumption
N/A
Resistance to chemical
attack
Resistance to abrasives
Reliability
By products
N/A
PAS 110
Achieves
Pasteurisation
Ease of operation
Safety of operation
Ease of commissioning
CAPEX
Stage Of Development
Suppliers/Reference Plants
Sustainability
Power Usage
Odour Potential
Chemical usage
None
Water usage
Noise
Hazard
Temperature
Pressure
Chemical N/A
Carbon footprint
Product competition
N/A
Product market security
N/A
High
OPEX
Established
CAMBI
Lillehammer (Norway), Verdal (Norway)
Cardiff WWTW (UK), Aberdeen WWTW(UK)
Veolia (Biothelys)
Saumur (France)
Chteau-Gontier (France)
Availability of UK Support
Feasibility
There is extensive experience of this technology within the waste water industry and more
recently it has been successfully applied to source segregated food wastes (Norway). The
technology provides the pasteurisation required by legislation, as well as improving digestate
quality and biogas production.
(CAMBI, 2011, Veolia, 2011)
CAMBI. 2011. Biowaste Treatment [Online]. Available: http://www.cambi.no/wip4/detail.epl?cat=10645 [Accessed 11/05/2012].
VEOLIA. 2011. Biothelys [Online]. Available: http://www.veoliawaterst.com/biothelys/en/ [Accessed 11/05/2012].
Process
Autoclave
Process Type
Objectives
Thermal (pre-treatment)
To pasteurise, clean and break-down the organic matter within the
feedstock, rendering it more amenable to digestion
Process Flow
Diagram
Steam
Heat Recovery
Autoclave 1
Feed
Buffer
Digester
Autoclave 2
Steam
Process
Description
An autoclave is a pressure vessel that steam-treats its contents at a

constant temperature and pressure, serving to pasteurise, clean and
break-down organic matter within the feedstock. After processing,
inorganic material and contaminants can be removed via mechanical
separation systems providing a pasteurised, organic rich feedstock for
anaerobic digestion.
The ability of this process to improve contaminant removal makes it
particularly relevant for MBT and food waste applications.
Benefits
Pasteurisation.
Easier removal of contaminants post
treatment.
Improved solids destruction, reducing
digestate mass.
Increased biogas yield.
Challenges
High temperature and pressure.
Feed solids %ds
N/A
pH
N/A
Temperature C
160
Pressure
5.2 bar
Throughput
attack
Reliability
By products
PAS 110
Ease of operation
Safety of operation
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
N/A
Unknown
Achieves
Pasteurisation
No data
available
No data
available
No data
available
Noise
Hazard
None
(feed preparation)
No data available
Temperature
Pressure
Chemical N/A
Carbon footprint
Product competition
N/A
N/A
CAPEX
No data
OPEX
No data available
available
Emerging
AeroThermal Limited
Feasibility
The first full scale plant to utilise this technology is currently being designed (see AeroThermal
Lee Mill example). This technology has the potential to greatly improve the quality of digestate
from MBT type processes and food waste applications. The odour potential associated with this
process is caused by the requirement to open the vessel after each batch, however this can be
contained with automated loading/emptying systems.
(AeroThermal Limited, AeroThermal Group, 2008)
AEROTHERMAL GROUP. 2008. AeroThermal's Solution [Online]. Available:
http://www.aerothermalgroup.com/aerothermal/aerothermals-solution.aspx [Accessed 09/05/2012.
AEROTHERMAL LIMITED. Municipal Solid Waste Processing [Online]. Aerothermal Limited. Available:
http://www.aerothermalgroup.com/aerothermal/municipal-solid-waste.aspx [Accessed 09/05/2012.
Process
Enzymic Liquefaction
Process Type
Biological pre-treatment
Objectives
To break-down the organic matter within the feedstock
Process Flow
Diagram
Hot water /
Steam
Feed
Process
Description
Enzymes
Pre-treatment
Temperature
control
Enzymatic
treatment
Digester
The REnescience process developed by DONG Energy utilises enzymes to

breakdown and separate the organic matter within the feedstock prior to
digestion. The enzymes convert the feedstock to an organic rich liquid
which can be easily separated from inorganic material and physical
contaminants. This system is therefore ideally suited for the pre-treatment
of mixed waste streams i.e. MBT.
The first stage in the process is a non-pressurised thermal treatment with
hot water or steam, which serves to open-up the biomass in order to make
it accessible to the enzymes. In the second stage enzymes are added to the
process to liquefy and further break down the biomass cell structure,
improving digestibility and separability. The third stage of the process
separates the bio-liquid from the remaining solid waste (which latter is then
split into a recyclable fraction, or fractions, and a potential RDF fraction).
A 1 tonne per hour pilot plant has been operating successfully in
Copenhagen (Denmark) since 2009, using untreated residual municipal
waste. Other C&I waste streams have also been processed.
Benefits
Improved digestate quality by
removal of contaminants.
Very high recovery of the organic
fraction of the residual waste into a
bio-liquid which is easily handled for
pumping, storage and transportation.
Increased digestibility and biogas
yield.
Low volume of solid digestate results
from the bio-liquid.
Challenges
No operational facilities within the UK.
Use of enzymes not yet widespread in the UK.
DONG Energy are searching for a partner or
partners to establish a commercial
demonstration plant in the UK.
Feed solids %ds
N/A
pH
N/A
Temperature C
<100oC
Pressure
Atmospheric
Throughput (m/d)
Dependent on
inputs
Use of enzymes
attack
Reliability
By products
N/A
PAS 110
Not compliant
on mixed waste
Ease of operation
Safety of operation
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
to be established
CAPEX
Confidential, but OPEX

Confidential, but
competitive
competitive
Pilot
Pilot plant operational in Copenhagen (Denmark)
Feasibility
This technology has the potential to greatly improve the quality of digestate from MBT type
processes, however it is not yet established at full scale. The construction of a full scale plant
is required to demonstrate the feasibility of this technology.
DONG Energy are currently examining the feasibility for the design, build and operation of a
commercial scale demonstration plant in the UK , and are seeking potential project partners.
Dong Energy,. 2012, RENESCIENCE [online] Available at http://www.dongenergy.com/REnescience/Pages/index.aspx. Accessed
13/06/2012
Process
FITEC Anaerobic digestion grit removal system
Process Type
Objectives
Process Flow
Diagram
Mechanical separation
To remove grit and other solid contaminants from the digester/digestate
Digestate return
Digester
Process
Description
Gravity
separator
Separated grit
and sediment
No pre-treatment process will be able to remove physical contaminants

entirely, and as such these contaminants will be transported into the
digester. These contaminants accumulate within the digester causing
mechanical problems and reducing the operational volume of the
digester. Any material carried over into the final digestate will reduce its
quality. This is particularly relevant for food waste and MBT applications.
The FITEC grit removal system utilises a mechanical scraper to
continuously remove settled grit and sediment from the bottom of the
digester, preventing grit build-up and improving digestate quality.
Within the digester a centrally mounted scraper arm continuously
rotates, forcing settled material to the outside of the digester where it is
discharged to a hopper in the digester floor slab. Collected material is
pumped to an external gravity separator where the grit is removed and
the separated liquid is returned to the digester.
Benefits
Improves digestate quality.
Continuous cleaning of the digester.
Reduced requirement for feedstock grit
removal.
Improves lifetime of mechanical
equipment within the digester.
Minimises digester volume loss due to
grit accumulation.
Challenges
Limits digester diameter to 18m.
Requires a flat digester floor.
(Finsterwalder Umwelttechnik GmbH & Co. KG, 2012)
Feed solids %ds
0 - 7%
pH
6-8
Temperature C
30-55
Pressure
Throughput (m/d)
1,5t/d
N/A
attack
Reliability
By products
Grit
PAS 110
Removal of
physical
contaminants
Ease of operation
Safety of operation
Sustainability
Power Usage
0.75kW / d
Odour Potential
Chemical usage
None
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
N/A
N/A
CAPEX
25,000
OPEX
(13m diameter)
Maturing
Finsterwalder Umwelttechnik GmbH & Co. KG: Langage Farm
Feasibility
This technology enables the continuous removal of settleable physical contaminants from the
digester. This improves digestate quality and compliance with the parameters of PAS 110 by
reducing the level of physical contaminants within the digestate. Grit and other contaminant
build-up within the digester is also reduced. However a specific digester design/build is
required.
FINSTERWALDER UMWELTTECHNIK GMBH & CO. KG. 2012. Digester Equipment [Online]. Available:
http://www.fitec.com/user/endigequip.html [Accessed 16/05/2012].
Process
FITEC Anaerobic digestion scum removal system
Process Type
Objectives
Process Flow
Diagram
Mechanical separation
To remove floating contaminants from within the digester
Filter
Digester
Process
Description
Separated
material
Digestate return
No pre-treatment process will be able to remove contraries entirely and

as such physical contaminants can be transported into the digester.
These contaminants then accumulate within the digester causing
mechanical problems and reducing the operational volume of the
digester. Any material carried over into the final digestate will impair its
quality. This is particularly relevant for food waste and MBT applications.
The FITEC scum removal system utilises a mechanical skimmer to
continuously remove floating contaminants and scum from the top of
the digester, preventing these materials from fouling mechanical
equipment and improving digestate quality.
Within the digester a centrally mounted skimmer continuously rotates
forcing settled material to the outside of the digester where it is pumped
to an external filter. The material is separated, contaminants discharged
to skip and the separated liquid is returned to the digester. The system
is self regulating and gas tight.
Benefits
Improves digestate quality.
Continuous cleaning of floating
contaminants from the digester
No need to clean feedstock perfectly
from plastics.
Reduces fouling of the mechanical
equipment within the digester.
Maximises digester capacity .
Challenges
Limits digester diameter to 18m.
Requires a solid digester roof.
(Finsterwalder Umwelttechnik GmbH & Co. KG, 2012)
Feed solids %ds
0-7%
pH
6-8
Temperature C
30-55
Pressure
Throughput (m/d)
5t/h
N/A
attack
medium
Reliability
By products
N/A
PAS 110
Removal of
physical
contaminants
Ease of operation
Safety of operation
Sustainability
Power Usage
2.5kW / h
Odour Potential
Chemical usage
None
Water usage
Noise
30dB/A 10m
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
N/A
N/A
CAPEX
70,000
OPEX
Maturing
Finsterwalder Umwelttechnik GmbH & Co. KG: Langage Farm
Feasibility
This technology enables the continuous removal of floating physical contaminants from the
digester. This improves digestate quality and compliance with the parameters of PAS 110, by
reducing the concentration of physical contaminants within the digestate. Contaminant build-up
within the digester is also reduced, minimising potential for fouling whilst maximising digester
volume. However a specific digester design/build is required.
FINSTERWALDER UMWELTTECHNIK GMBH & CO. KG. 2012. Digester Equipment [Online]. Available:
http://www.fitec.com/user/endigequip.html [Accessed 16/05/2012].
Process
Gravity belt thickening
Process Type
Objectives
Process Flow
Diagram
Thickening (physical)
To increase solids concentration
Feed
Belt thickener
Thickened digestate
Liquor
Process
Description
Within a belt thickener the digestate is evenly distributed over a porous

cloth belt which is moved by a series of rollers. Water is removed by
gravity as the belt carries the digestate towards the discharge. Water
removal is improved by a series of plough blades along the belt that fold
the digestate allowing released water to drain through the belt.
Thickened sludge is removed from the belt by a scraper system, and the
belt then passes through a wash cycle.
Polymer addition is usually necessary in order to achieve good results.
Using this system digestates can be thickened to 5-7% dry solids with a
solid capture rate of up to 98%.
Benefits
Increased solids concentration.
Reduced transport volume of solid
fraction.
Challenges
Filtrate (liquor) disposal is still
required.
Feed solids %ds
>0.5%
pH
>6.5, <7.5
Temperature C
Ambient
Pressure
Ambient
Throughput (m/d)
attack
Reliability
By products
PAS 110
Ease of operation
Safety of operation
Large range of
unit sizes
available
Polyelectrolyte
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
Low(washing,
polymer make-up
and carrier)
Noise
Hazard
Temperature
Pressure
(localised
mechanical)
Liquor - volume
dependent on
degree of
thickening
No effect on
status
Carbon footprint
Chemical
Product competition
CAPEX
50k +
OPEX
Established
Ashbrook Simon Hartley
Numerous WWTW reference sites
Ovivo Water
Feasibility
Belt thickening technology is widely implemented to good effect in the waste water industry to
reduce the solids handling volume. Consideration must be given to the press liquor as further
treatment may be required prior to reuse or disposal.
Tchobanoglous, G.Burton, F.L. and Stensel, D.H. 2004. Waste Water Engineering Treatment and Reuse.4th Edition. New
York:McGraw Hill
Ashbrook Simon- Hartley, 2012. Aquabelt [online] available at: http://www.as-h.com/uk/en-gb/aquabelt.aspx [Accessed
28/02/2012]
Process
Centrifuge thickening
Process Type
Objectives
Process Flow
Diagram
Thickening (physical)
To increase solids concentration
Centrifuge
Feed
Thickened digestate
nedndeCake
Liquor
Process
Description
Centrifugal thickening is a mechanical process that uses centrifugal

force, from the rapid rotation of a cylindrical bowl, to achieve solid liquid separation. Sludge is fed continuously into the rotating bowl of
the centrifuge. Solid particles are forced towards the bowl wall by
centrifugal force, where they are moved by an internal scroll towards
the solids discharge. Liquid effluent is discharged from the bowl via
adjustable weir plates.
Polymer addition is usually necessary in order to achieve good results.
Using this system digestates can be thickened to 5-7% dry solids with a
solid capture rate of up to 98%.
Benefits
Increased solids concentration.
fraction.
Challenges
Centrate (liquor) disposal is still
required.
Feed solids %ds
>1%
pH
>6.5, <7.5
Temperature C
<80
Pressure
Ambient
Throughput (m/d)
attack
Reliability
By products
PAS 110
Ease of operation
Safety of operation
20 m/h +
Polyelectrolyte
Liquor, volume
dependent on
degree of
thickening
No effect on
status
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
(washing,
polymer make-up
and carrier)
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
CAPEX
80k +
OPEX
Established
Alfa Laval
Euroby
GEA Westfalia
MSE Hiller
High
Feasibility
Centrifuge technology is widely implemented to good effect in the waste water industry to
reduce the solids handling volume. Consideration must be given to the centrate liquor as
further treatment may be required prior to reuse or disposal.
York:McGraw Hill
Ashbrook Simon- Hartley, 2012. Decanter Centrifuge [online] available at: <http://www.as-h.com/uk/engb/centrifugedecanter.aspx> [Accessed 29/02/2012]
Process
Belt Press
Process Type
Objectives
Process Flow
Diagram
Dewatering (physical)
Separate solid and liquid phases of digestate
Press
Feed
Cake
Liquor
Process
Description
Belt presses use the shear forces and mechanical pressure generated
between two opposing porous cloth belts to de-water digestate. The
process typically consists of three stages; gravity, low pressure and high
pressure. Digestate is continuously fed into the gravity section where
free water is removed via gravity. This section can include vacuum
assistance. Low pressure is then applied by two porous cloth belts
before the feed is subjected to high pressure and shear forces as the
belts pass through a series of rollers. Final de-watered cake is
removed from the belts by scraper blades. Liquor permeates through
the belts and is collected. Typically a cake of 18 25% dry solids can
be achieved.
Benefits
Increased solids and liquor
concentration.
fraction.
Challenges
Filtrate (liquor) disposal is still
required.
Feed solids %ds
>0.5%
pH
>6.5, <7.5
Temperature C
Ambient
Pressure
Ambient
Throughput (m/d)
attack
Reliability
By products
PAS 110
Ease of operation
Safety of operation
Large range of
unit sizes
available
Polyelectrolyte
Liquor - volume
dependent on
degree of
thickening
No effect on
status
Sustainability
Power Usage
Odour Potential
Chemical usage
Medium
Water usage
Low(washing,
polymer make-up
and carrier)
Noise
Hazard
Temperature
Pressure
(localised
mechanical)
Chemical
Carbon footprint
Product competition
CAPEX
100k +
OPEX
Low
Established
Ovivo Water
Siemens
Numerous WWTW
Aquatreat
reference sites
Bioclere Technology International
High
Feasibility
Belt press technology is widely implemented to good effect in the waste water industry to
reduce the solids handling volume. Consideration must be given to the press liquor as further
treatment may be required prior to reuse or disposal.
Ashbrook Simon- Hartley, 2012. Aquabelt [online] available at: http://www.as-h.com/uk/en-gb/aquabelt.aspx [Accessed
28/02/2012]
Huntley DT. Improving waste treatment and minimisation with electrokinetic geosynthetic technology. Electrokinetic Ltd
York:McGraw Hill
Process
Centrifuge
Process Type
Objectives
Process Flow
Diagram
Dewatering Physical
To separate solid and liquid fractions and reduce transport volumes
Centrifuge
Feed
Cake
Liquor
Process
Description
Centrifugal thickening is a mechanical process that uses centrifugal

force, from the rapid rotation of a cylindrical bowl, to achieve solid liquid separation. Sludge is fed continuously into the rotating bowl of
the centrifuge. Solid partials are forced towards the bowl wall by
centrifugal force, where they are moved by an internal scroll towards
the solids discharge. Liquid effluent is discharged from the bowl via
adjustable weir plates.
A final dewatered cake of 18 20% dry solids can be achieved.
Benefits
Increased solids and liquor
concentration.
fraction.
Challenges
Centrate (liquor) disposal is still
required.
Feed solids %ds
>1%
pH
>6.5, <7.5
Temperature C
<80
Pressure
Ambient
Throughput (m/d)
attack
Reliability
By products
PAS 110
Ease of operation
Safety of operation
20 m/h +
Polyelectrolyte
Liquor, volume
dependent on
degree of
thickening
No effect on
status
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
(washing,
polymer make-up
and carrier)
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
CAPEX
80k +
OPEX
Established
Alfa Laval
Euroby
GEA Westfalia
MSE Hiller
High
Feasibility
Centrifuge technology is widely implemented to good effect in the waste water industry to
reduce the solids handling volume. Consideration must be given to the centrate liquor as
further treatment may be required prior to reuse or disposal.
York:McGraw Hill
Ashbrook Simon- Hartley, 2012. Decanter Centrifuge [online] available at: <http://www.as-h.com/uk/engb/centrifugedecanter.aspx> [Accessed 29/02/2012]
Process
Hydro Cell
Process Type
Objectives
To separate solids and liquid fractions, reduce transport volumes and
create a potential fuel
Process Flow
Diagram
Digestate Fibre
Additive
Mixer
Press
Cake
Liquor
Process
Description
Within the HydroCell process the digestate is mixed with a high calorific
value additive in order to increase the energy content and improve ease
of dewatering. Typical additives include wood dust and coal dust.
Once the additive has been mixed with the digestate it is de-watered by
a hydraulic press. Dry solids contents of up to 80% have been achieved.
The improved energy content of the digestate additive mixture makes
this process particularly relevant as a pre-treatment for incineration.
Benefits
Separation of solid and liquid fractions.
High solids content of cake.
Improved energy content.
Challenges
Liquor requires further treatment.
Availability and cost of additive.
Feed solids %ds
12 24%
pH
Temperature C
Ambient
Pressure
Localised
mechanical
Throughput (m/d)
attack
Reliability
unknown
By products
liquor
PAS 110
No effect
Ease of operation
Safety of operation
Sustainability
Power Usage
No
Odour Potential
No
Chemical usage
No
Water usage
No
Noise
Hazard
data
data
data
data
available
available
available
available
No data available
Temperature
Pressure
Chemical
Carbon footprint
No data available
Product competition
No data available
No data available
CAPEX
No data
OPEX
No data available
available
Near Commercial
HydroCell Technologies, Ireland
Medium
Feasibility
If incineration is the final disposal route for the digestate fibre and a suitable additive is readily
available, then this technology provides a simple method for turning the digestate into a
valuable fuel for energy recovery.
Hydrocell Technologies Ireland, Enhanced Mechanical Sludge Dewatering. Hydrocell Technologies Ireland.
OReilly, D., 2011. Hydrocell Technologies . Waste Treatment System. U.S. Pat 8,061,057 B2.
Process
Bucher Press
Process Type
Objectives
To increase solids and liquor concentration and reduce transport
volumes
Process Flow
Diagram
Bucher Press
Feed
Cake
Liquor
Process
Description
The Bucher press is a hydraulically driven cylinder-piston system.

The press cylinder is filled by a central inlet. Once filled, the sludge is
compressed by the piston forcing the liquid fraction through tubular
filter cloths suspended between the piston and the cylinder. The piston
then retracts while the cylinder rotates to loosen the cake. This process
is repeated until the desired solids content is achieved.
Once complete the casing is opened and the cake is discharged by the
piston. Bucher report that dewatering up to 50% dry solids can be
achieved.
Benefits
Separation of solid and liquid fraction.
High solids content of cake.
Challenges
Batch operation.
Feed solids %ds
>1%
pH
N/A
Temperature C
Ambient
Pressure
Localised
mechanical
Throughput (m/d)
No data
available
attack
Reliability
unknown
By products
liquor
PAS 110
No effect on
status
Ease of operation
Safety of operation
Sustainability
Power Usage
Odour Potential
Chemical usage
No data available
Water usage
No data available
Noise
No data available
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
CAPEX
High
OPEX
low
Emerging
Bucher
High
Feasibility
The Bucher press is a well-established technology in the food processing industries. Although
the technology is transferable, current experience of its application on digestate is limited.
There is current interest in applying this technology within the UK water industry. These
presses have a higher capital cost than other dewatering technologies, however offer potential
to provide high dry solids content. A detailed cost benefit analysis would therefore be required
to determine the feasibility and financial viability for a specific application.
http://www.bucherunipektin.com/html/en/5814.html
Process
Electrokinetic Dewatering
Process Type
Objectives
(physical)
To remove water content from digestate to reduce solids handling
volume
PFD
Applied voltage
Electrokinetic(EK)
Cell
Feed
Cake
Liquor
Process
Description
In an Electrokinetic dewatering system digestate is fed into a cell

containing pairs of electrodes connected to a DC power supply. Water
within the digestate is removed by electro-osmosis and electrophoresis
in the electrical field applied between the electrodes. Once released the
water migrates to the cathode where it is collected.
Dry solids contents of up to 55 % have been produced in laboratory
scale systems. Electrokinetic systems have also been shown to reduce
pathogens, with trials achieving an 11 log reduction in Salmonella spp.
Trials have been undertaken at Long Reach STW (Thames Water) by
EKG and Ashbrook Simon-Hartley in the use of electrokinetic belts to
improve the dewatering efficiency of belt presses. Initial reports claim to
increase the product dry solids above 30%.
Benefits
Potential dewatering and
disinfection in a single unit.
High solids content achieved.
Challenges
Scale up from bench to industry.
High power consumption.
Removal of separated water.
Feed solids %ds
Any
pH
Any
Temperature C
Pressure
Throughput (m/d)
attack
Reliability
By products
Ambient
Ambient
PAS 110
Sanitisation
Ease of operation
Unknown at full
scale
Unknown at full
scale
Unknown at full
scale
Safety of operation
None
Liquor
Sustainability
Power Usage
128 kWh/m
Odour Potential
Unknown at full
scale
Chemical usage
None
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Unknown at full
scale
Product competition
Unknown at full
scale
Unknown at full
scale
CAPEX
No data
OPEX
No data available
available
Research
None
Low
Feasibility
Low
This technology offers promising results, however it is too early to determine its feasibility at
full scale.
Agnew, A., Et al. (2011) Electrokinetic remediation of plutonium-contaminated nuclear site wastes: Results from a pilot-scale
on-site trial. Journal of Hazardous Materials: 186: 1405 1414
Huang, J., Elektorowicz, M. and Oleszkiewicz, J.A., Dewatering and disinfection of aerobic and anaerobic sludge using an
elektrokinetic (EK) system
Lamont-Black, J., et al., 2005. THE DEVELOPMENT OF IN-SITU DEWATERING OF LAGOONED SEWAGE SLUDGE USING
ELECTROKINETIC GEOSYNTHETICS (EKG). 10th European Biosolids and Biowaste Conference. UK, November 2005. Aqua
Enviro Technology Transfer
Process
Membrane Purification
Process Type
Objectives
Purification (physical)
To purify the liquid phase of digestate to enable direct discharge of
purified water (permeate), and concentration of nutrients for further
treatment or utilisation.
Process Flow
Diagram
Feed
Ultrafiltration
(UF)
Reverse Osmosis
(RO)
UF Concentrate
Process
Description
Permeate
RO Concentrate
Membrane purification uses a selectively permeable membrane as an

inter-phase in order to achieve separation between two liquid phases.
Separation is driven by a pressure gradient across the membrane.
Membrane purification is usually installed downstream of solid-liquid
separation (see dewatering) on the liquid phase. Typically a two stage
process is installed using ultrafiltration membranes followed by final
purification by reverse osmosis membranes. Ultrafiltration membranes
have a pore size of 0.1m 5nm and are installed to remove the
remaining particles and dispersed colloids. The final stage in the
purification process is reverse osmosis. The reverse osmosis membranes
have an effective pore size of <1nm and are used to remove dissolved
salts and any remaining organics. The products of the process are
purified water (permeate) and two separate nutrient rich concentrates.
Benefits
Purified water potentially acceptable
for direct discharge.
Concentrated liquors lead to reduced
volumes for further treatment (N
stripping) or possible use as liquid
fertilisers.
Challenges
Concentrate disposal is still required,
although reuse may be possible (as
process water).
Membranes must be protected from
particulates and large volumes of
solids to prevent fouling and physical
damage.
Fouling.
Feed solids %ds
<1%
pH
Temperature C
Pressure
>6.5, <7.5
<80
UF 200 kPa, RO
4000kPa
Throughput (m/d)
Modular units
available
Cleaning
dependant on
membrane
material
attack
Reliability
By products
PAS 110
Ease of operation
Safety of operation
Sustainability
High (1625kWh/m)
Odour Potential
Chemical usage
Water usage
(washing, poly
make-up and
carrier)
Noise
Power Usage
Concentrate
No effect on
status
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
CAPEX
OPEX
Maturing
A3 Water Solutions GmbH
Osmonics, Inc.,
Wehrle
Wychwood Water Systems LTD
Gea filtration
Veolia Water
Medium
Feasibility
Membrane purification of digestate is not fully established within the UK. However there are
several full scale plants within Europe. Careful consideration must be given to the nature of
the digestate and the cleaning regime that will be required to prevent membrane fouling.
York:McGraw Hill
A3 Water Solutions gmbh, 2012. Digestate Treatement. [online] available at http://www.a3gmbh.com/_NewsBASE/content_a3/frame_english.php
Process
Rotary Drying
Process Type
Objectives
Drying (Thermal)
To decrease moisture content, to reduce transport costs and increase
marketability
Process Flow
Diagram
Rotary
Drier
Hot Gases
Feed
Cyclone
Exhaust
Gas
Treatment
Product recycle
Dried
Product
Process
Description
Within a rotary drier digestate fibre is contacted with hot gases in order
to dry the product by means of convection.
The rotary drier itself consists of a cylindrical drum which is rotated
about its axis. Flights within the drying drum pick up and cascade the
digestate. The drum is mounted on a slight slope from the horizontal to
facilitate transport of the dried product along its length. The feed to the
drier is blended with dried product to give a feed of approximately 65%
dry solids (DS) to improve movement within the drum. Waste gases are
passed through a cyclone to recover solids before further treatment.
Note that significant amounts of ammonia may be contained within the
exhaust gas stream.
Final product dry solids of up to 95% can be achieved. Screening can be
built in to the process to give a homogenous product pellet size.
Benefits
Reduced volume of digestate for
transport and storage.
Improved marketability as a
fertiliser/soil conditioner.
Effective pathogen kill.
Challenges
High temperature operation.
Large capital investment.
Reduced nutrient content of final
product.
Gas treatment required.
Risk of explosive atmosphere within
drying plant.
Feed solids %ds
18%
pH
N/A
Temperature C
~400
Pressure
Throughput (m/d)
Low
attack
Reliability
By products
Condensate,
exhaust gases
PAS 110
Achieves
Pasteurisation
Ease of operation
Safety of operation
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
CAPEX
OPEX
Established
Andritz AG Tilbury and Glasgow WWTWs
Swiss Combi GmbH Ringsend WWTW, Dublin
Vandenbroeck Isle of Man WWTW
Siemens
Feasibility
Rotary dryers are used to good effect within the waste water industry.
York:McGraw Hill
Siemens. 2012. Convective Thermal Drier Sub-systems. [Online] Available at:
<http://www.water.siemens.com/en/products/sludge_biosolids_processing/sludge_dryers/Pages/Convective_Thermal_Dryer_Su
b_SSystem.aspx> [Accessed 13/03/2012]
Process
Belt Drying
Process Type
Objectives
Drying (Thermal)
To decrease moisture content to reduce transport costs and increase
marketability
Process Flow
Diagram
Hot Gases
Digestate
Fibre
Process
Description
Belt Dryer
Dried
Product
Within a belt dryer digestate is contacted with hot gases in order to dry
the product by means of convection.
The (previously separated) digestate fibre is fed into the dryer where it
is evenly distributed over the drying belt by an extruder. The extruder
produces digestate strands in order to increase surface area and provide
a uniform size. The drier belt passes through a series of successive
chambers of increasing temperature. At the end of the belt digestate is
dropped onto a second belt which runs back through the drier,
underneath the first belt, to complete the drying process and cool the
product. Dried product is discharged from the drier at the end of the
second belt. Product is discharged at up to 90% DS and at a
temperature below 40C.
As the digestate is not agitated during the drying process the risk of
creating an explosive dust atmosphere within the drier is significantly
reduced. This improves the safety and operability of the process.
Benefits
Reduced volume of digestate for
transport and storage.
Improved marketability as a
fertiliser/soil conditioner.
Effective pathogen kill.
Challenges
Large capital investment.
Reduced nutrient content of final
product.
Feed solids %ds
18%
pH
Temperature C
400
Pressure
Throughput (m/d)
Low
attack
Reliability
By products
Condensate,
exhaust gases
PAS 110
Achieves
Pasteurisation
Ease of operation
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
Safety of operation
CAPEX
OPEX
Established
Sevar
Andritz AG
Feasibility
Belt dryers are used to good effect within the water and wood pulp industries. The feasibility of
this technology will be dependent on the installation and the end use of the dried product.
York:McGraw Hill
Sevar. The SEVAR Belt Drier. [online] Available at: http://www.sevar.de/en/drying-plant/belt-dryer/ [Accessed 14/04/2021].
Process
J-Vap
Process Type
Objectives
Process Flow
Diagram
Dewatering and Drying

To separate the solid and liquid fractions contained within the digestate
J - Vap
Feed
Dried Fibre
Liquor
Process
Description
J-Vap is the trade name of a dewatering/drying system produced by

Siemens. The system is a two stage process combining a filter press and
a vacuum evaporation step to produce a dried product within a single
unit. It is claimed solids concentrations of up to 99% can be achieved.
Digestate is pumped into the filter chambers, and once full, the
diaphragms are inflated to mechanically de-water the digestate. Once
de-watered, heated pressurised water is pumped to the heat exchangers
contained within the filter plates. At the same time a vacuum is created
on the cake side of the filters. This vacuum lowers the boiling point of
the remaining water in the digestate. Once the cycle is completed the
filter plates are separated and the dried digestate is discharged.
A pasteurisation step can be included if required. After the drying cycle
the vacuum can be turned off and the temperature raised to meet the
time and temperature requirements for pathogen kill.
As the process operates in batches buffer storage will be required.
Benefits
Dewatering and drying in a single unit.
High solids content leads to reduced
transport volumes.
Challenges
Liquor treatment required.
Reports of mechanical failures of plate
frames.
Batch operation.
Feed solids %ds
>1%
pH
N/A
Temperature C
50
Pressure
Vacuum
Throughput (m/d)
Cleaning
attack
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
Noise
Hazard
Temperature
Reliability
By products
PAS 110
Pressure
Chemical
Carbon footprint
Product competition
Ease of operation
Safety of operation
Liquor
Pasteurisation
can be included
CAPEX
No data
OPEX
No data available
available
Maturing
Siemens Installations at WWTW in America
High
Feasibility
High
The J-Vap provides a single stage low temperature alternative to conventional dewatering and
drying processes. A number of full scale plants are currently in operation in the USA.
8.0
Siemens.,2011. J-Vap Dewatering and Drying System [Online}. Available at <www.siemens.com/jvap > [Accessed
12/03/2012]
Process
Solar Drying
Process Type
Objectives
Process Flow
Diagram
Drying (Thermal)
To increase the solids content of digestate
Condensate
(To atmosphere)
Feed
Process
Description
Solar drying bed
Dried digestate
Solar drying uses a combination of forced ventilation and solar energy to

de-water digestate. Waste heat from a CHP can also be utilised via
under floor heating. The feed to the process can be fed with either
whole digestate or de-watered fibre.
The digestate is fed into greenhouses where it is distributed across the
drying bed. Digestate is turned and ventilated to increase efficiency and
reduce odours. The greenhouses operate as a batch or semi-continuous
process. The final product is a dried digestate exceeding 50% dry solids.
Benefits
Increased concentration.
Reduced transport volume.
No liquor treatment required.
Challenges
Large surface area required.
UK Climate may restrict
application(Most current applications in
Spain or Southern France).
Feed solids %ds
>1%
pH
>6.5, <7.5
Temperature C
Pressure
Ambient
Throughput (m/d)
None
attack
Reliability
By products
None
PAS 110
No effect on
status
Ease of operation
Safety of operation
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
CAPEX
OPEX
Emerging
Thermo System Langage Farm AD (UK)
Veolia Solia TM - Multiple references in France
Degremont - Heliantis TM - Multiple references in France
Medium
Feasibility
This technology provides a low Opex solution for dewatering digestate. However a large land
area is required. There is one reference plant utilising this technology within the UK (Langage
Farm). Most operational plants of this type are located in southern European countries with
warm climates. It is not yet known how this technology will operate with the climate in the UK.
Thermo Systems http://www.thermo-system.com
Veolia Water Technologies http://www.veoliawaterst.com/solia/en/
Process
Surface Scraped Heat Exchanger (HRS)
Process Type
Objectives
Concentration (Thermal)
To remove water from digestate liquor and increase the concentration of
nutrients in the final product
Process Flow
Diagram
condensate
Acid
Separated digestate
liquor
Process
Description
Surface scraped
evaporator
Concentrated fertiliser
Evaporation utilises waste heat from the CHP to achieve concentration

of the digestate liquor.
Surface scraped evaporators are designed to overcome fouling issues
associated with the evaporation of digestate. The evaporators use a
shell and tube configuration. The interior surface of the heat exchanger
tubes is constantly cleaned by internal scrapers to reduce fouling and
increase heat transfer efficiency.
The digestate liquor is dosed with acid prior to evaporation to prevent
ammonia loss within the evaporator. The volume of acid dosed is
dependent on the digestate and the desired retention time. Within the
evaporator the liquor is concentrated to approximately 20% dry solids.
This concentrate can then be mixed with the (previously) separated
digestate fibre to produce a nutrient rich solid fertiliser.
Trials have indicated that the condensate from the process is suitable
for direct discharge to ground water, although further treatment may be
required for certain applications. Alternatively it can be recycled as
process water.
Benefits
Reduced transport volume.
Potentially no further treatment of
condensate required.
Concentrated nutrient rich product.
Use of heat eligible for RHI.
Challenges
Acidic product may limit available land
bank.
Feed solids %ds
1-2%
pH
Temperature C
Pressure
Acidic
50 - 70C
Vacuum
Throughput (m/d)
Modular units
available
attack
Reliability
By products
PAS 110
Sustainability
(350kWhtherm /ton
evaporated)
Odour Potential
Chemical usage
Water usage
(cleaning)
Noise
Power Usage
Hazard
Temperature
Pressure
Chemical
Ease of operation
Safety of operation
Condensate
No effect on
status
CAPEX
Emerging
HRS Process Systems SSE Barkip
Carbon footprint
Product competition
OPEX
Dependent on
availability of
waste heat
High
Feasibility
Full scale plants utilising this technology for the concentration of pig slurry are operational and
achieving good results in Europe. A newly commissioned plant in Scotland will use the
technology for the concentration of digestate liquor (See Technology Example SSE Barkip).
Should this technology prove successful at the Barkip plant it provides a very feasible method
for treating digestate liquor and producing a balanced fertiliser product. Eligibility for the RHI
also provides another potential income stream for the plant. Consideration will need to be
given to the acidic nature of the final product and the affect this may have on the available
land bank.
HRS.,2012. HRS Heat Exchangers: Providing the technology for heat transfer applications [Online] Available at
<http://www.hrs-heatexchangers.com> [accessed 15/03/2012]
Process
Incineration
Process Type
Objectives
Thermal
The complete combustion of organic solids in order to minimise volume
and recover energy
Off Gas
Process Flow
Diagram
Feed
Process
Description
Incineration
Ash
Incineration is the complete conversion of all combustible elements

within the fuel to oxidised end products, primarily carbon dioxide, water
and ash. However complete combustion is very difficult to achieve and
therefore other chemical species, such as CO, NOx and pure carbon, are
likely to be produced. Flue gasses from the process will require
treatment before they can be discharged to atmosphere. Ash produced
from the process can be recycled for use within road construction, used
for the production of concrete, or sent to landfill. It may also be possible
to recover phosphorus from the ash by acid leaching.
It is beneficial to feed the incinerator with as dry a cake as possible.
This means that digestates must be dewatered prior to incineration in
order to reduce their moisture content. Additional fuel may be required
to dry the digestate before combustion can occur. The volume of
additional fuel required to initiate and sustain combustion will be
dependent on the calorific value of the digestate, moisture content and
the efficiency of the incinerator. Energy recovery from the process,
although desirable, is not always possible.
Several incinerator designs exist but the most widely employed system,
fluidised bed incineration, consists of a vertical cylindrical shell
containing a sand bed which is fluidised by air to enable combustion.
digestate is fed directly into the fluidised bed to provide rapid
evaporation and combustion. If operated correctly, and provided the
calorific value of the digestate is sufficiently high, there is no need for
additional fuel after start-up. Heat from the process can be used to
produce steam for electricity generation.
Co-incineration with municipal solid waste may provide a means of
increasing the heating value, such that additional fuel is not required
and energy recovery can be achieved. Thermal destruction may be the
only available disposal option for digestates which cannot be applied to
land due to non-compliance with legislation.
Benefits
Volume reduction.
Destruction of pathogens and toxic
compounds.
Possible energy recovery.
Challenges
High operating cost.
Complex operation.
Potential environmental impact of
residuals (exhaust air).
Loss of fertiliser potential
Public perception.
Feed solids %ds
High as possible
pH
Temperature C
800
Pressure
Atmospheric
Throughput (m/d)
attack
Reliability
By products
Flue gases, Ash
PAS 110
N/A
Ease of operation
Safety of operation
CAPEX
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
OPEX
Established
Veolia Water, Pyrofluid - Numerous references in France
Envirotherm GMBH
ThyssenKruup Shell Green (UK)
High
Feasibility
Incineration technology is well established. However capital and operating costs are high and
as such it is usually only feasible for large plants or where land application of digestates is not
possible due to digestate quality or land bank availability.
York:McGraw Hill
Veolia, 2011. Pyrofluid [online] available at < http://www.veoliawaterst.com/pyrofluid/en/> [accessed 07/04/2012]
Process
Gasification
Process Type
Objectives
Process Flow
Diagram
Thermal
Thermal destruction of organics and production of syngas
Syngas
Feed
Process
Description
Gasification
Ash
Gasification can be used to convert organic matter, such as coal, wood

or biomass, to a mixture of gases consisting mostly of carbon monoxide
and hydrogen, known as syngas. Reactions take place at high
temperatures with carefully controlled amounts of oxygen, air or steam.
The syngas can be burned in a gas engine to produce heat, and ash/
char from the process can be used for road construction, production of
concrete, or sent to landfill.
Gasification of traditional fuels such as wood and coal is well
established, and the process has also been used for municipal solid
waste. Full scale gasification of dried sewage sludge has also been
shown to be economic. A full scale plant is operational in Germany, with
another being commissioned and two more planned.
However the use of gasification for digestate is not well documented. As
most of the organics have already been released during digestion the
value of digestate as a fuel for gasification is relatively low. Digestate
must be dried and ideally pelletized before it can be gasified, placing an
additional energy demand on the process. Pilot studies on digestate
from pig manure have shown that energy recovery can be achieved but
that the additional gain over AD alone is low.
Thermal destruction may be the only available disposal option for
digestates which cannot be applied to land due to non-compliance with
legislation.
Benefits
Volume reduction.
Destruction of pathogens and toxic
compounds.
Renewable heat and energy
generation.
Challenges
High operating cost.
Complex operation.
Ash disposal to landfill.
Loss of fertiliser potential.
Feed solids %ds
70% +
pH
N/A
Temperature C
700- 1000
Pressure
Ambient
Throughput (m/d)
attack
Reliability
By products
Ash
PAS 110
Achieves
Pasteurisation
Ease of operation
Safety of operation
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
CAPEX
OPEX
Pilot
Kopf SynGas GmbH & Co
Veolia Water (technical advisors)
High
Feasibility
Gasification is a well-established technology, however research into its use for digestate
treatment is still at the pilot stage. Further research is required to determine whether the
additional energy gain outweighs the capital cost and additional processing requirements to
prepare the feed.
Kuligowski, K and Luostarinen, S., 2011. Thermal Gasification of Manure. Baltic MANURE WP6 Energy Potentials.
Prapaspongsa, T., 2009. Energy production, nutrient recovery and greenhouse gas emission potentials from integrated pig
manure management systems. Waste Management and Research, 00:1-12
Process
Wet Air Oxidation (WAO)
Process Type
Objectives
Process Flow
Diagram
Thermal
Destruction of organic solids
Off Gas
Feed
Process
Description
WAO
Liquid
effluent
Mineral
sludge
Wet air oxidation (WAO) is a well-established technique for the

treatment of high strength industrial effluents. WAO is achieved at
elevated temperature and high pressure to prevent evaporation. The
oxygen source for the reaction can be air, oxygen-enriched air or pure
oxygen. Under these conditions the solubility of oxygen is increased
allowing the reactions to occur within the liquid phase (rather than in
the gaseous phase as with normal combustion processes). The
conditions also enable chemical oxidation of mineral components within
the feed.
The outputs from the process are an off-gas, a biodegradable liquid
phase and a mineral sludge (less than 5% organic content). Off-gases
consist mainly of CO2, O2 and NH3 and will require further treatment
before discharge to atmosphere. The mineral sludge can be dewatered
and used for land reclamation or potentially as a secondary raw material
for building and construction. The dewatering liquor and WAO liquid
effluent both require further treatment before reuse or discharge.
Solids reduction of up to 95% can be achieved. If heat recovery is
implemented it is possible to make the process auto thermal. A catalyst
(copper II ions) can be used to lower the operating temperature if
required.
Several full scale plants are currently operational in Europe treating
digested sewage sludge.
Thermal destruction may be the only available disposal option for
digestates which cannot be applied to land due to non-compliance with
legislation.
Benefits
Gaseous emissions free from toxins
and particulates.
Greener image than incineration.
Total oxidation achieved.
Renewable heat and energy
generation.
Challenges
Relatively high temperature and
pressure.
Feed solids %ds
>2%
pH
N/A
Temperature C
200 - 300
Pressure
70-150 bar
Throughput (m/d)
Catalyst if
required,
quantity
unknown
attack
Reliability
No data
available
By products
Mineral
sludge/Liquid
effluent/off gas
PAS 110
Achieves
Pasteurisation
Ease of operation
No data
available
Safety of operation
No data
available
No data
available
Sustainability
Power Usage
No
Odour Potential
No
Chemical usage
No
Water usage
No
Noise
No
Hazard
data
data
data
data
data
available
available
available
available
available
Temperature
Pressure
Chemical
Carbon footprint
No data available
Product competition
No data available
No data available
CAPEX
No data
OPEX
No data available
available
Established
Veolia (Athos) Installed at North Brussels WWTW
Siemens (Zimpro)
Feasibility
High
WAO presents a feasible alternative to incineration. Full scale plants are operational in Europe
treating sewage sludge digestates. As with incineration this technology is likely to be best
suited to large scale urban installations where no land bank is readily available.
Chauzy, J., 2010. Wet Air Oxidation of Municipal Sludge: Return Experience of the North Brussels Waste Water Treatment Plant.
Water Practice Technology. 5
Siemens., Zimpro Wet Oxidation: Innovative Technology for Difficult Waste Treatment Problems. [Online] Available at
<http://www.water.siemens.com/SiteCollectionDocuments/Product_Lines/Zimpro/Brochures/ZP-WAO-BR-0906.pdf> [Accessed
16/03/2012]
Veolia., 2011. Athos. [Online] Available at < http://www.veoliawaterst.com/athos/en/> [Accessed 16/03/2012]
Process
Pyreg
Process Type
Objectives
Process flow
diagram
Slow pyrolysis
To convert digestate into syngas and biochar
Heat
Feed
Process
Description
Syngas
Pyrolysis
reactor
Burner
Exhaust gas
Char + Ash
The Pyreg process is a modular pyrolysis process. Pyrolysis processes
heat the feed material in an oxygen-free atmosphere breaking down
organics within the feed into char and syngas. The term biochar refers
to char derived from the pyrolysis of organic matter.
The Pyreg process uses a twin screw pyrolysis reactor. Material is fed
into the reactor via a gas tight rotary valve. Material is moved along the
reactor by the twin screws ensuring uniform heating and residence time.
Syngas created by the process is burnt in a flameless burner (FLOX )
to reduce emissions. Exhaust gases from the burner are fed back to
provide heat for the process before discharge. Once operational the
process is thermally self-sufficient.
Approximately 70% of the feed mass is destroyed within the reactor
with the remainder recovered as a mix of carbon-rich char and ash. The
biochar has potential value as a soil amendment or as a feedstock for
growing media production.
The Pyreg process is contained within a standard shipping container.
The possibility of installing a turbine to recover electricity from the
exhaust gasses, and make the process entirely self-sufficient, is
currently under investigation. Research is also being undertaken into the
possibility of increasing biogas yield and ease of dewatering by blending
biochar with the digester feedstock.
Benefits
Carbon capture.
Soil amendment - reduced application
of compound fertilisers.
Biochar value as a growing media
constituent.
Renewable heat generation.
Small footprint.
Modular units.
Challenges
Acceptance of the new technology.
Securing a market for biochar.
Establishing a PAS and QP for biochar.
Limited process experience.
High feed solids content required.
Feed solids %ds
55 to 70
pH
Temperature C
Pressure
Throughput
attack
Reliability
By products
PAS 110
Ease of operation
Safety of operation
NA
450 - 800
<0.5bar
1200 tds/annum
(modular)
N/A
NA
No data
available
Biochar, Ash
and exhaust
gasses
N/A
More
operational data
required
Sustainability
3.5kW (selfsufficient
operation
possible)
Odour Potential
None
Chemical usage
None
Water usage
30 litres/h
Noise
Power Usage
Hazard
Temperature
Pressure
Chemical NA
Carbon footprint
Product competition
Negative,
sequesters
1200t/a
equivalent of CO2
None
Emerging market
CAPEX
300 - 450
OPEX
GBP85k/a
Pilot
Supplier : Pyreg
Sonnenerde GmbH, Austria (paper sludge)
Delinat Institute, Switzerland 2 plants (research and farm waste)
Low
Feasibility
The Pyreg technology is proven for biomass feedstocks at full scale and digestate at pilot scale.
The size and modular design of the process make it accessible to a range of plant sizes,
however the digestate must be dried prior to processing. Ultimately the feasibility of this
technology will be dependent on the market for the biochar produced.
GMBH, P. (2011). "PYREG." Retrieved 10/05/2012, from http://www.pyreg.com/English.html.
PYREG (2011) Biomass to Biochar using Pyregs Slow Pyrolysis Technology.
York:McGraw Hill
Process
Composting
Process Type
Objectives
Biological
To stabilise the solid fraction of the digestate to convert it into a soil
improver or growing media constituent
Process Flow
Diagram
Digestate fibre
Process
Description
Composting Plant
Compost
Composting of the solid (separated) fibre digestate fraction enables

breakdown of the organic components and fixes the nitrogen to nitrates,
although some may be lost as gaseous ammonia. As the organics
decompose the compost heats to 50 - 70C, due to the exothermic
nature of the reaction, and sanitisation can be achieved. This results in
a high quality product which can be marketed as compost.
A number of different technologies exist including aerated static pile,
windrow, and in-vessel composting (IVC). Each of these technologies
has its own advantages and disadvantages but the process steps are
essentially the same. 1) Pre-processing/addition of bulking material 2)
high rate decomposition, aeration by addition of air, mechanical turning,
or both 3) further curing and storage and 4) post-process screening.
Processes accepting any kind of animal by-product (including most food
wastes) need to be contained, in compliance with the Animal ByProducts Regulations.
The separated fibre digestate can either be composted on its own or cocomposted with standard composting feedstocks e.g. wood chip, green
waste etc. As an additive to standard composting the digestate provides
a source of nitrogen, phosphorus, magnesium and iron, as well as
moisture. The standard composting feedstocks provide a bulking agent,
as well as improving the C:N ratio and consistency of the final product.
Co-composting is therefore beneficial for both waste streams.
Compost typically has a lower fertiliser replacement value than
digestate, however it is a more readily accepted product for sale as a
bagged soil improver for gardeners or landscapers. Compost can also
have a longer land application season.
Benefits
Improved marketability as a soil
improver/compost.
Increased solids content leads to
reduced transportation costs.
Improved product stability, portability
and materials handling.
Challenges
Large footprint.
Potential ammonia emissions.
Feed solids %ds
>18%
pH
N/A
Temperature C
60
Pressure
Ambient
Throughput (m/d)
attack
Reliability
By products
N/A
PAS 110
N/A
Ease of operation
Safety of operation
Sustainability
Power Usage
Odour Potential
Chemical usage
None
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
CAPEX
OPEX
Established
Ecological Waste Apparatus
SKM Enviros
High
Feasibility
Composting provides a simple way of improving the solid digestate fraction and adding
potential value to the digestate. Composting of anaerobically digested sewage sludge is a well
established and well understood technology. However depending on the quality of the dewatered fraction and the final outlet it may not be required.
Chartered Institute of Wastes Management (2002) Biological Techniques in Solid Waste Management and Land Remediation.
Various authors. CIWM Report. Chartered Institution of Wastes Management, 9 Saxon Court, St Peters Gardens,
Northampton, NN1 1SX, UK.
Evans, TD., 2008. An independent review of sludge treatment processes and innovations. 4th Australian Water Association
Biosolids Conference. Adelaide, 2008.
Kayhanian, M. Lindenauer, K. Hardy, S. and Tchobanoglous, G. (1991) Two-stage process combines anaerobic and aerobic
methods. BioCycle 32 (3) 48-53.
York:McGraw Hill
Von Felde, D. and Doedens, H. (1999) Full-scale experiences with mechanical-biological pretreatment of municipal solid waste
and landfilling. Waste Manage. Res. 17(6), 520-526. Special Issue. Paper from Proceedings 3rd International Swedish Landfill
Research Symposium, held Lulea, Sweden, 6-8 Oct. 1998. Diaz, L. (ed).
Process
Reed Beds
Process Type
Objectives
PFD
Biological
Dewatering, pasteurisation and mineralisation of digestate
Digestate
Feed
Reed Bed
Conditioned
digestate
Liquor
Process
Description
Digestate is fed directly to a sealed basin containing a bed of aggregate

on which the reeds grow. Drains are installed under the basin to collect
the filtered liquor which can be used as process/irrigation water. The
combined effect of this drainage and evapotranspiration de-waters the
sludge to 30 40% DS. Further reduction is achieved through
mineralization of the digestate.
Reed beds provide treatment over a period of 10-15 years and during
this period the beds must be cycled between loading and rest
(treatment) periods. After the treatment period the beds are dug out,
the sludge removed, and the process restarted. A number of reed beds
are therefore usually operated cyclically to provide continuous
treatment. During the treatment period sanitisation is achieved, up to 6
log pathogen kill. This increases the marketability of the digestate and
potential application area.
Benefits
Low power and OPEX.
Sanitisation.
Stabilisation.
Volume reduction.
Challenges
Large land area required.
Long operational time (10-15
years) to produce a stable product.
Feed solids %ds
0.5 5 %
pH
Temperature C
Ambient
Pressure
Ambient
Throughput
20-60 kg
ds/m/yr
N/A
attack
Reliability
High
By products
Liquor
PAS 110
Ease of operation
Safety of operation
Achieves
sanitisation
Sustainability
Power Usage
Odour Potential
Chemical usage
None
Water usage
None
Noise
None
Hazard
Temperature None
Pressure None
Chemical None
Carbon footprint
(neutral)
Product competition
CAPEX
1.5m /ha
OPEX
Maturing
ARM Biosolids
High
Feasibility
This technology is widely used for the treatment of digested sewage sludges in Denmark. If
land is available to construct the reed beds this technology may provide a low OPEX method of
producing a sanitised, mineralised and de-watered digestate product.
ARM Biosolids. Sludge Treatment in Reed Beds. 2012. [Online] Available at

<http://www.armbiosolids.co.uk/what_is_sludge_treatment_in_reed_beds.html> [Accessed 28/03/2012]
Nielsne, S. and Willoughby, N., 2005. Sludge Treatment in Reed Bed Systems and Recycling of Sludge and Environmental
Impact. In: Aqua Enviro Technology Transfer, 10th European Biosolids and Biowaste Conference.UK, November 2005, Aqua
Enviro Technology Transfer.
Process
Biological oxidation
Process Type
Objectives
Biological
To biologically oxidise organic matter and ammonia (NH3) within the
digestate to reduce liquor strength for discharge or further treatment.
Process Flow
Diagram
Treated effluent
Reactor
Feed
Sludge
Air / oxygen
Process
Description
Biological oxidation can be used to remove the organic matter, which is

measured as biological oxygen demand (BOD), within the digestate and
converts ammonia to nitrate (nitrification). The process can be applied
to the whole digestate, but is most commonly used on the separated
liquor. The process can be managed to only remove BOD or to remove
both BOD and ammonia.
Within the process digestate is aerated in the presence of bacteria which
convert organic matter to CO2, H2O and new bacteria. Biological
nitrification utilises nitrifying bacteria to oxidise the ammonia within the
digestate to nitrate (NO3-). An anoxic stage can be included to convert
the nitrate to nitrogen if desired. This can reduce operating costs and
make the process more stable. However the nitrate is lost and hence the
value of the effluent as a fertiliser is lost. Process selection will
therefore be dependent on the desired product, a treated effluent for
discharge, a nitrified effluent for use as a fertiliser or a partially treated
effluent to simplify downstream processing.
Removing the BOD and ammonia will reduce the charges for discharging
the liquor to sewer if this is the chosen disposal route. Alternatively if
sufficient treatment is provided the liquor may be suitable for direct
discharge to groundwater. Nitrate is more stable than ammonia and
therefore can improve the digestates value as a fertiliser. The reaction
is sensitive to temperature and shock loading. Once the digestate has
been nitrified it can be concentrated by evaporation without the risk of
releasing large quantities of ammonia.
The most common reactor configurations are sequencing batch reactor
(SBR), membrane bioreactors (MBR) or aeration followed by dissolved
air flotation (DAF). Sludge from the process can be fed back into the
digester.
Benefits
Nitrified effluent can be better utilised
as a fertiliser.
Effluent is suitable for concentration by
evaporation.
Reduced disposal cost.
Challenges
High power consumption.
Feed solids %ds
N/A
pH
Temperature C
Pressure
Throughput (m/d)
6.5 7.5
8+
Ambient
attack
Reliability
By products
PAS 110
Ease of operation
Safety of operation
Sustainability
(aeration)
Odour Potential
Chemical usage
Water usage
Noise
(blowers)
Hazard
Temperature
Power Usage
Sludge
No effect on
status
Pressure
Chemical
Carbon footprint
Product competition
N/A
N/A
CAPEX
OPEX
Established
Wehrle
Veolia
Numerous WWTW and Leachate
Treatment Plant
SKM Enviros
High
Feasibility
Biological oxidation is one of the most commonly employed methods of wastewater treatment.
The technology is well established and proven. However the operating costs can be high. If no
outlet to land is available biological oxidation provides a proven method to reduce the cost of
liquor disposal.
Fuchs W, Et al. 2010. Digestate treatment: comparison and assessment of existing technologies. Venice 2010, Third
International Symposium on Energy from Biomass and Waste.
York:McGraw Hill
Process
Algal Pond/Photo bio reactor
Process Type
Objectives
Process Flow
Diagram
Biological
To produce algal biomass to enable biofuel production
Liquid digestate
Bio Gas
Algal Pond /
Photo bio reactor
Irrigation water
Enriched Bio
Gas
Algal biomass
Process
Description
The nutrients contained within the liquid fraction of the de-watered

digestate can be used as a feedstock for algae. Lipids from the algae
can be separated and converted into biofuel, and the remaining algal
biomass can either be fed back to the digester or sold as animal feed.
Algae are photosynthetic autotrophic organisms that fix carbon dioxide
from the atmosphere. The biogas created from the AD process can
therefore also be used as a carbon source capturing up to 95% of the
CO2 within the biogas. Removing CO2 from the biogas by passing
through the algal biomass also improves the quality of the biogas.
Water from the process can be used as process water or for irrigation.
Algae can be cultivated in either simple ponds or in photo bioreactors
which achieve process intensification but at increased capital costs and
complexity. Waste heat from a CHP can also be used to improve process
performance.
Benefits
Improves quality of liquid fraction.
Produces algae which can either be
sold or converted into biodiesel.
Removes CO2 from biogas.
Challenges
Large surface area required for ponds.
Careful control required for
bioreactors.
Feed solids %ds
Liquor
pH
Species
dependent
Temperature C
15 30
Pressure
Ambient
Throughput (m/d)
attack
Reliability
By products
Algal Biomass,
process water
PAS 110
No effect
Ease of operation
Safety of operation
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Negative
Product competition
CAPEX
No data
OPEX
No data available
available
Near commercial
Algae Cake (photo bioreactors)
Advanced Algae (APAR, photo bioreactors)
Algae Food and Fuel
Low
Feasibility
A full scale pilot/demonstration plant is currently operational in the Netherlands. Further
research is required to assess the feasibility of this technology and the market for biofuels and
the algal biomass.
Algae Food and Fuels, 2009. Hallum [online] Available at: <http://www.algaefoodfuel.nl/english/projects/hallum/ >[Accessed
05/03/2012]
Algecake Technologies Corporation ,2008, [online] Available at: < http://www.algaecake.com/> [Accessed 05/03/2012]
AlgEn, algal technology centre. [online] Available at:: < http://www.algen.si/> [Accessed 05/03/2012]
Iyovo GD, Du G, Chen J (2010) Poultry Manure Digestate Enhancement of Chlorella Vulgaris Biomass Under Mixotrophic
Condition for Biofuel Production. J Microbial Biochem Technol 2: 051-057.
Iyovo GD, Du G, Chen J (2010) Sustainable Bioenergy Bioprocessing: Biomethane Production, Digestate as Biofertilizer and as
Supplemental Feed in Algae Cultivation to Promote Algae Biofuel Commercialization. Journal of Microbial & Biochemical
Technology 2: 100-106.
Rhodes, C.J. (2011). Making fuel from algae: identifying fact amid fiction. In: The Science of Algal Fuels: Phycology, Geology,
Biophotonics, Genomics and Nanotechnology. Eds.: R. Gordon& J.Seckbach. Dordrecht, Springer
Solarix, 2012. First harvest innovative Algae Project. [Press Release], Available at: http://www.solarix.eu/en/news/101
[Accessed 05/03/2012]
Process
Bioethanol production
Process Type
Objectives
Process Flow
Diagram
Biological
To convert separated fibre into bioethanol
Feed
(digestate fibre)
Pre
Treatment
Enzymic
Hydrolysis
Sulphuric acid / Sodium

hydroxide
Process
Description
Fermentatio
n
Ethanol
Lignin / waste biomass
Digestate fibres are first pre-treated with a dilute solution of either

sulphuric acid or sodium hydroxide. Fibres are then broken down into
simple sugars by enzymic hydrolysis. Ethanol can then be produced
from the sugars by fermentation.
Research has shown that digestate fibre (derived from animal manure)
is better than switch grass and comparable to corn stover as a feedstock
for bioethanol production. This shows promising results and further
research is required into the feasibility of other digestate feedstocks.
The lignin produced as a by-product is a valuable biomass that can also
be used to produce energy.
It has also been shown that freshwater and nutrients used for
bioethanol production from traditional energy crops can be replaced
with de-watered liquor. Using digestate liquor in this manner has been
shown to significantly increase ethanol yields.
Benefits
Conversion of digestate fibre into
valuable fuel source.
Potential for reuse of digested
liquor.
Challenges
Early stage of development.
Chemical consumption.
Feed solids %ds
>18%
pH
Acidic
Temperature C
100-150
Pressure
Ambient
Throughput (m/d)
No data
available
No data
available
No data
attack
available
No data
available
Reliability
No data
available
By products
Lignin
PAS 110
N/A
Ease of operation
Safety of operation
No data
available
Sustainability
Power Usage
No
Odour Potential
No
Chemical usage
No
Water usage
No
Noise
No
data
data
data
data
data
available
available
available
available
available
Hazard
Temperature No data available
Pressure No data available
Chemical No data available
Carbon footprint
Product competition
No data available
No data available
No data available
CAPEX
No data
OPEX
No data available
available
Research
None available
Feasibility
Low
This technology shows promising results, however further research is required to determine its
feasibility at full scale.
(Alkan-Ozkaynak, 2011, Ballesteros, 2010, Gao, 2010, Teater, 2011, Yue, 2010, Yue, 2011)
ALKAN-OZKAYNAK, A. K., K, G. 2011. Anaerobic digestion of thin stillage for energy recovery and water reuse in corn-ethanol
plants. Bioresource Technology, 102, 9891 - 9896.
BALLESTEROS, M. S., F. BALLESTEROS, I. MANZANARES, P. NEGRO, M, J. MARTNEZ, J, M. CASTAEDA, R. DOMINGUEZ, J, M,
O 2010. Ethanol Production from the Organic Fraction Obtained After Thermal Pretreatment of Municipal Solid Waste
Applied Biochemistry and Biotechnology 161, 423 - 431.
GAO, T. L., X. 2010. Using thermophilic anaerobic digestate effluent to replace freshwater for bioethanol production.
Bioresource Technology, 102, 2126 - 2129.
TEATER, C. Y., Z. MACLELLAN, J. LIU, Y. LIAO, W. 2011. Assessing solid digestate from anaerobic digestion as feedstock for
ethanol production. Bioresource Technology, 102, 1856 - 1862.
YUE, Z. T., C. LIU, Y. MACLELLAN, J. LIAO, W. 2010. A sustainable pathway of cellulosic ethanol production integrating
anaerobic digestion with biorefining. Biotechnology and Bioengineering, 105, 1031 - 1039.
YUE, Z. T., C. MACLELLAN, LIU, Y. J. LIAO, W. 2011. Development of a new bioethanol feedstock Anaerobically digested fiber
from confined dairy operations using different digestion configurations. Biomass and Bioenergy, 35, 1946 - 1953.
Process
Microbial Fuel Cells (MFC)
Process Type
Objectives
Process Flow
Diagram
Biological
Digestate polishing and power production
Power
Feed
(Whole digestate)
Process
Description
MFC
Polished digestate
Microbial Fuel Cells (MFC) are a novel technology that enables the
production of bioelectricity from the biological oxidation of organic
matter. The technology utilises the ability of particular microorganisms
to transfer electrons directly to an anode during respiration. The
reactions take place under anaerobic conditions.
The electrons are transferred from an anode (installed in the reaction
chamber) to a cathode via an external resistance.
Protons are transferred to the cathode chamber by either a salt bridge
or a proton exchange membrane (PEM) where they are combined with
oxygen to produce water.
Laboratory scale trials on digestate have shown that the system is
capable of removing 3.99kg COD/md with a power density of 42w/m.
Benefits
Power production.
COD removal.
Challenges
Cathode stability.
Membrane costs.
Transition from laboratory scale to
industrial application.
Feed solids %ds
pH
Further analysis
required
Temperature C
Further analysis
required
Pressure
Further analysis
required
Throughput (m/d)
Further analysis
required
Further analysis
required
Further analysis
attack
required
Further analysis
required
Reliability
Further analysis
required
By products
Water
PAS 110
Ease of operation
Safety of operation
Sustainability
Power Usage
Net generation
Odour Potential
Further analysis
required
Chemical usage
Further analysis
required
Water usage
Further analysis
required
Noise
Further analysis
required
Hazard
Further analysis
required
Temperature Further analysis
required
Pressure Further analysis
required
Chemical Further analysis
required
Carbon footprint
Product competition
Unknown
Unknown
CAPEX
No data
OPEX
No data available
available
Research
None
Feasibility
Low
This technology offers promising results at laboratory scale, however it is too early to
determine its feasibility at full scale.
Aelterman P, et al. (2006) Microbial Fuel Cells for Wastewater Treatment. Water Science & Technology 54:9-15
Peixoto L. (2012) Microbial Fuel Cells for autonomous systems: kinetics and technological advances in wastewater treatment
and sensor applications. Ph.D. University of Minho
Process
Process Type
Objectives
Struvite Precipitation
Nutrient recovery
To recover struvite (magnesium ammonium phosphate) for use as a
product
PFD
Fluidised Bed
Reactor
Liquid Digestate
pH
Adjustment
Treated Digestate
Magnesium
Dosing
Struvite
Process
Description
Magnesium, ammonium and phosphate can be combined to form a solid

commonly known as struvite (magnesium ammonium phosphate or
MAP). The reaction is highly dependent on pH, with the optimum range
for precipitation around pH10. However at values above pH9, ammonia
comes out of solution and is lost through evaporation. For most
digestates the reaction is also limited by the concentration of
magnesium ions.
It is therefore often necessary to artificially increase the pH of the
digestate and to add magnesium ions. pH can be increased by either
dosing with bases, in the form of sodium hydroxide or magnesium
hydroxide, or by aeration to de-gas the digestate. Dosing with
magnesium hydroxide has the advantage of increasing both the pH and
the magnesium ion concentration, but also prevents the pH and ion
concentration from being optimised independently. Magnesium ion
concentration can also be increased by the addition of magnesium
chloride.
Precipitation is typically carried out in fluidised bed reactors to produce
solid granules such as struvite, which has value as a chemical fertiliser.
Struvite contains equimolar amounts of ammonium and phosphate.
Since the digestate often contains more ammonium than phosphate the
treated liquor can be sent to a subsequent ammonia removal process to
recover the remaining ammonia. Otherwise additional treatment may
be required before discharge or further use. Under certain conditions
struvite can precipitate within the digester pipework causing fouling.
Benefits
Recovery of struvite which has value as a
fertiliser.
Struvite is recovered as easily handled
pellets.
Prevents fouling of pipe work and plant .
Challenges
Contamination with solids.
Market security.
Complexity.
Feed solids %DS
<1%
pH
8-9
Temperature C
Pressure
Throughput (m/d)
attack
Reliability
By products
12-25
Ambient
PAS 110
Ease of operation
Saftey of operation
No effect
Sustainability
Power Usage
Odour Potential
High (ammonia
due to high pH)
Chemical usage
High
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
(chemical)
Product competition
CAPEX
No Data
OPEX
No Data Available
Available
Near Commercial
Unitika Ltd. - Phosnix - Reference sites installed in Japan
DHV Water BV Crystalactor
NuReSys
Wehrle
Full scale plant installed at Slough WWTW
Low
Feasibility
The feasibility of this technology is dependent on the price that can be obtained for the
struvite. This process may not be viable for all installations as the volume of Struvite that can
be produced is determined by the composition of the digestate. However if a secure market
for the struvite can be sourced this presents another possible source of income for anaerobic
digestion plants.
(Parsons S, 2001, Giesen, 2010, Driver, 1998, Nawa, Evans, 2009)
DRIVER, J. 1998. Phosphates recovery for recyling from sewage and animal wastes Phosphorus & Potassium, 17 - 21.
EVANS, T. D. 2009. Recovering ammonium and struvite fertilisers from digested sludge dewatering liquors. Resource Recovery
Not Wastewater Treatment Conference. London: Aqua-Enviro.
GIESEN, A. 2010. Crystallization Process Enables Environmental Friendly Phosphate Removal at Low Costs.
NAWA, Y. P-recovery in Japan the PHOSNIX process. Unitika Ltd. Environment & Engineering Div.
PARSONS S, A. W., F. DOYLE, J. OLDRING, K. CHURCHLEY, J. 2001. ASSESING THE POTENTIAL FOR STRUVITE RECOVERY AT
SEWAGE TREATMENT WORKS. Environmental technology, 22, 1279 - 1286.
Process
Process Type
Objectives
Process Flow
Diagram
Ammonia Stripping
Nutrient recovery
To recover ammonium sulphate for use as product
Air
Digestate
Liquor
Stripping
Column
Treated
digestate
out
Process
Description
Sulphuric Acid In
Acid
Scrubber
Ammonium sulphate out
Ammonia is removed from digestate liquor by stripping with air at

increased temperature and pH. Air is contacted with the digestate to
absorb the ammonia which is less soluble at the operating conditions.
Ammonia is then recovered from the process air by acid scrubbing with
sulphuric or nitric acid to produce ammonium sulphate or nitrate
respectively. Once the ammonia has been recovered the air is returned
to the start of the process.
Heat for the process can be provided by a CHP. pH adjustment of the
digestate is usually by chemical addition.
Contact between the digestate and air is typically achieved by countercurrent flow in a packed column. This provides good transfer but is
susceptible to fouling. Promising results have been achieved recently by
diffusing air though the digestate in stirred tank reactors. This
eliminates fouling issues.
Biogas can be used in place of air to strip the ammonia. Recent research
suggests that if stripping is carried out within the digester it may be
possible to regulate the ammonia concentration within the digester.
The remaining liquor will probably require further treatment before it
can be discharged.
Benefits
Ammonia removed from digestate
potentially removing restrictions on land
application, due to nitrogen content.
Concentrated ammonium sulphate stream
can be used as liquid fertiliser or feedstock
for other processes.
Challenges
High temperature and pH.
Precipitation of ammonium sulphate within
washing column.
Fouling.
Feed solids %ds
<1%
pH
8-12
Sustainability
Power Usage
Odour Potential
Temperature C
Pressure
Throughput (m/d)
attack
Reliability
By products
35-80
Ambient
Chemical usage
Water usage
Noise
Hazard
Temperature
PAS 110
Ease of operation
Reduced N Load
Saftey of operation
CAPEX
No Data
OPEX
Available
Near Commercial
Colsen b.v.
3XR inc
Pressure
Chemical
Carbon footprint
(chemicals)
Product competition
Product market
security
No Data Available
High
Feasibility
Ammonia stripping can be used to produce a nitrogen rich fertiliser which can be sold as a
product. This technology is well established within the chemical industry. The feasibility of this
technology will be dependent on whether a secure outlet for the ammonium sulphate can be
found.
Anasruron DFD, Bade O, Korner I. Nitrogen recovery from biogas plant digestates via solid-liquid separation and stripping.
Technologies/systems for different manure and organic waste treatment options
Colsen b.v., AMFER [PDF] Available at: <http://www.colsen.nl/uk/brochure/index.html>
Fuchs W, Et al. 2010. Digestate treatment: comparison and assessment of existing technologies. Venice 2010, Third
International Symposium on Energy from Biomass and Waste.
Walker M, et al. 2011. Ammonia removal in anaerobic digestion by biogas stripping: An evaluation of process alternatives using
a first order rate model based on experimental findings. Chemical Engineering Journal 178: 138 - 145
Process
Membrane Contactor
Process Type
Objectives
Process Flow
Diagram
Nutrient recovery (Chemical)

To recover ammonia from digestate liquor
Sulphuric Acid
Base
Membrane
Contactor
Feed
Process
Description
Treated
digestate
Ammonium
Sulphate
By increasing the temperature and/or the pH of the digestate the
solubility of ammonia can be reduced. The ammonia can then be
removed by contacting the digestate with sulphuric acid, which reacts
with the ammonia to form ammonium sulphate.
Digestate and sulphuric acid are fed, counter currently, on opposite
sides of a microporous hydrophobic membrane. Gaseous ammonia is
removed across the air filled pores of the membrane. Mass transfer is
driven by a concentration difference between the two liquid phases. The
hyrophobicity and small pore size of the membrane prevent liquid flow
across the membrane ensuring the two phases remain separate. The
remaining liquor will probably require further treatment before it can be
discharged.
Benefits
Single step process for recovering
ammonia as ammonium sulphate.
Challenges
Membrane fouling.
Feed solids %ds
<1%
pH
10
Temperature C
40-55
Pressure
Ambient
Throughput (m/d)
Modular units
available
attack
Reliability
By products
N/A
PAS 110
N/A
Ease of operation
Safety of operation
Sustainability
Power Usage
Odour Potential
Chemical usage
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
Product competition
CAPEX
No data
OPEX
No Data Available
available
Research
Membrana (Liqui-Cel)
Low
Feasibility
Membrane contactors potentially allow for removal of ammonia in a single stage unit. Removal
efficiencies of up to 95% have been achieved in lab scale systems. Further information on
chemical requirement and operability at large scale is required.
Membrana. (2009) Using TransMembraneChemiSorption (TMCS) for Ammonia Removal from Industrial Waste Waters
Process
Ion Exchange
Process Type
Objectives
Process Flow
Diagram
Nutrient recovery (chemical)

To recover an ammonium rich fraction which can be used as a fertiliser
Process
Description
Stage 1: Feed
Treated
digestate
out
Stage 2:
RegenerationRegeneration
solution In
Ammonia
enriched solution
out
Digestate
In
A number of materials can be used to selectively adsorb ammonia from

the digestate. These materials include zeolites, clays and resins. The
adsorption media can then be regenerated to recover the ammonia.
Regeneration can be achieved by a number of techniques including,
nitric acid washing, sodium chloride washing or biologically. The
technique used is dependent on the adsorption material and the desired
product.
Adsorption is carried out in a packed column, once the adsorption media
is saturated, the column is taken offline and regenerated. Adsorption
can therefore either be operated as a batch process using a single
column or a series of multiple columns can be sequenced to provide
continuous operation.
The remaining liquor will probably require further treatment before it
can be discharged.
Benefits
Recovery of concentrated ammonia.
Challenges
Fouling of adsorbent bed.
Maintaining bed capacity after multiple
regeneration cycles.
Feed solids %ds
<0.5%
pH
Neutral, effect
dependant on
media
Temperature C
Ambient, effect
dependant on
media
Pressure
Ambient
Throughput (m/d)
dependant on
regeneration
technique some
can recycle
attack
Reliability
By products
PAS 110
Ease of operation
Safety of operation
CAPEX
Sustainability
Power Usage
No data available
Odour Potential
Chemical usage
Water usage
Noise
Hazard
Temperature
Pressure
Chemical
Carbon footprint
(chemical)
Product competition
OPEX
Maturing
Thermo Energy, ARP (resin with brine or sulphuric acid
regeneration)
Enpar Technologies Limited, AmmEL (zeolite with brine solution
for regeneration, followed by electrochemical oxidation to
produce N2)
Carbtrol (resin)
NanoChem
Medium
Feasibility
This technology is well established in other industries, although there is little experience in
digestate applications. A pilot plant in the UK is operational at Didcot STW. Any issues of
fouling within the column will need to be resolved to allow the technology to develop further.
The feasibility of this technology will be dependent on whether a secure outlet for the
ammonium sulphate can be located.
Cooney, L.E. et al., 1999. Ammonia Removal from Wastewaters Using Natural Australian Zeolite. I. Characterization of the
Zeolite. SEPARATION SCIENCE AND TECHNOLOGY, 34(12), pp. 2307 2327
Maurer, M. et al. Nitrogen Recovery and reuse
Seed, P.L. et al., a novel ion-exchange/electrochemical technology for the treatment of ammonia in wastewater. Enpar
Technologies Inc.
Thornton, A, et al., 2006. Ammonium removal from digested sludge liquors using ion exchange. School of water Sciences
Cranfield University.
EvTEC., 2000. Environmental technology verification report for ammonia recovery process. American Society of Civil Engineers.
Process
Process Type
Objectives
Process Flow
Diagram
Chemical
To raise the pH of the sludge in order to achieve pathogen kill
Digestate
Fibre
Mixer
Stabilised product
Lime
Process
Description
Alkaline stabilisation raises the pH of the digestate in order to achieve

pathogen kill and neutralise odours (H2S). Lime is commonly used as the
alkali.
Lime can be added as liquid lime prior to dewatering (pre-treatment) or
as powdered lime (quicklime) after dewatering (post-treatment). In
both cases good mixing is required to ensure proper treatment.
Post-treatment is usually the preferred option as the quicklime reaction
is exothermic, the lime dose is lower, and no additional water is added
to the sludge. The final texture of the de-watered cake can also be
improved. Pre-treatment can also cause damage to dewatering
equipment through abrasive wear and scaling.
In areas of acid soil, lime-stabilised digestate can be very valuable to
farmers. However in areas of neutral soils lime addition can affect trace
element balances. Careful consideration must therefore be given to the
final outlet of the digestate.
In the extreme, the addition of lime can cause ammonia to be released
from digestate due to the increased pH, causing odour issues.
Benefits
Pathogen kill.
Improved digestate quality.
Simple process.
Suppression of H2S.
Challenges
Potential ammonia release (odour).
Not suitable for application to all soil
types.
High chemical requirement.
Feed solids %ds
pH
11 +
Temperature C
50 (for post
treatment)
Pressure
Ambient
Sustainability
Power Usage
Odour Potential
Chemical usage
Throughput (m/d)
Noise
Hazard
attack
Reliability
By products
PAS 110
Ease of operation
Safety of operation
High (150
250kg lime /
TDS)
None
Pathogen kill
(6 log)
Water usage
High (pretreatment)
Temperature
Pressure
Chemical
Carbon footprint
Product competition
Area dependent
CAPEX
OPEX
Established
SKE Solutions
Numerous installations in UK WWTW
Sodimate INC
High
Feasibility
Lime stabilisation is widely used in the water industry for stabilisation and enhancement of
sewage sludges. The technology is well proven, simple and easy to operate. However
consideration must be given to the final destination of the product and the potential for release
of gaseous ammonia which must be managed.
Evans, TD., 2008. An independent review of sludge treatment processes and innovations. 4th Australian Water Association
Biosolids Conference. Adelaide, 2008.
http://www.britishlime.org/tech_sewage01.php
York:McGraw Hill
www.wrap.org.uk

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Desk top study on digestate enhancement and treatment

Enhancement and treatment of

A review of enhancement techniques, processing options and novel

Project code: OMK006 - 002

Date: Nov 2012

WRAPs vision is a world without waste,

Written by: Pell Frischmann Consultants Ltd

Enhancement and treatment of digestates from anaerobic digestion

Enhancement and treatment of digestates from anaerobic digestion

Enhancement and treatment of digestates from anaerobic digestion

Anaerobic digestion. Process of controlled decomposition of organic matter under

Molecular oxygen available.

No available source of molecular oxygen.

Condition at which an exothermic reaction is self sustaining and no additional energy is

Methane generated by anaerobic digestion.

Gas generated by an anaerobic digestion process. Typically composed of 60% methane

Biological oxygen demand. Defined as the amount of oxygen required by aerobic

Chemical oxygen demand. Defined as the amount of oxygen required to chemically

Dry solids (ds)

Membrane bioreactor. The combination of a membrane process with a suspended

Mechanical Biological Treatment: waste processing facility that combines a mechanical

Enhancement and treatment of digestates from anaerobic digestion

a critical temperature for a specified period of time.

Reverse Osmosis: A membrane filtration technology that utilises a selective reverse

Ultra Filtration: A membrane filtration technology that utilises a selective ultrafiltration

Enhancement and treatment of digestates from anaerobic digestion

51 AD facilities operating on waste including food waste.

Enhancement and treatment of digestates from anaerobic digestion

WRAP has acknowledged the need to raise awareness of digestate enhancement

Enhancement and treatment of digestates from anaerobic digestion

Enhancement and treatment of digestates from anaerobic digestion

3.0 Digestate Enhancement

Digestate refers to the material produced by the process of anaerobically digesting

Nitrogen: 2.3 - 4.2 kg/tonne.

Why Use Enhancement Techniques?

The majority of digestate produced in the UK is spread to agricultural land as fertiliser,

Enhancement and treatment of digestates from anaerobic digestion

The key aims of digestate enhancement techniques are to:

increase the value of the digestate;

Enhancement and treatment of digestates from anaerobic digestion

4.0 Digestate Enhancement

Pre-Digestion Enhancement Techniques

Pre-treatment systems employed upstream of anaerobic digestion can be used to enhance

4.1.1 Thermal Hydrolysis

4.1.2 Autoclave Systems

Enhancement and treatment of digestates from anaerobic digestion

4.1.3 Enzymic Liquefaction

4.1.4 In-Vessel Cleaning Systems

Enhancement and treatment of digestates from anaerobic digestion

Enhancement and treatment of digestates from anaerobic digestion

Post-Digestion Enhancement Techniques

Table 1. Digestate Enhancement Techniques

Drying (Rotary Drying)

Drying (Belt drier)

Dewatering (Belt press)

Evaporation (scraped surface heat exchangers)

Dewatering (Bucher press)

Purification (Ultrafiltration and Reverse Osmosis)

Conversion (Wet air oxidation)

Ammonia recovery (Stripping + Scrubbing)

Ammonia recovery (Membrane Contactor)

Biofuel Production (Algae)

Ammonia recovery (Ion Exchange)