5th AnnualGrowingtheMargins/3rd Annual Canadianfarm&FoodBiogasConference London.

Ontario London Ontario

Feedmixture(Recipe)developmentformixedwastedigesters
PresentedBy:AshwaniKumar,P.Eng. P dB A h iK PE Sr.ProcessEngineer Feb28,2011 OVIVO IGWE

Ovivoataglance

Atrueglobalbusiness TheonlyglobalPureWater dedicatedsolelytowater, Company,focusedonwater. wastewaterandrenewable energyfromwaste. 1500employeesin5 continentsand21countries. 1,500employeeson5 continentsand21countries. Waterexpertisein17 industries. Mostextensivetechnology portfolio;bringingexpertise tf li b i i ti together Supportedthrough15 GlobalCentersof Excellence. Technology Supply Design TechnologySupply,Design Builders,Completesystem providers
2

200yearsinthemaking

Biomethanation Expertise/Structure

GlobalWaterEngineering Global Water Engineering Limited(GWE)

GLOBALWATERENGINEERINGorGWE isagroupofcompaniesspecializedin industrialwastewatertreatment,waterrecycling,digestionofbiomass,sludges , y g, g , g andslurries,biogasproductionandreuse,andcarboncredits. GWE designsandbuildstailormadesolutionsthatmeettheclientsneeds.

Biomethanation Expertise/Structure

GLV GWE

Createdbytwoleadingglobal companiesinindustrial GLV d wastewatertreatment,GLV and GlobalWaterEngineeringLimited (GWE) OvivoGWE,anindustrial wastewatertreatment,wateruse, andgreenenergysolutions and green energy solutions providerfortheNorthAmerican marketplace.

Technologyexpertise AdvancedADprocess Productintegration 500+ADreferences f IndustrialandmunicipalTechnology,

ProductsServices:OakvilleON,MontrealQC,AustinTX,Belgium ProductsServices:OakvilleON,MontrealQC,Austin Europe&Asia

GLVoffices GWE/GW&Eoffices GWE/GW&E offices Agents,licenseesand partnersworldwide

OVIVOIGWEAdvantage
1. Completeprojectwrapup 2. PreTreatment 3. Pretreatmentenhanceddigestion(RAPTORTM) 4. Solidseparation 5. Gasutilization 5 Gas utilization 6. Digestate treatment.

QubecProjects
Quebec1
Location: ProjectType: Capacity: Substrate: Landfillsite PPP(51%public,49%Private) 20to25000t/yr 20 to 25000 t/yr SSO Slaughterhousesludge Commercial,Institutionalresidues Upgrading,compression,usedincity trucksandbuses k db Mechanicaldewatering Liquidandsolidfertilizer

Biogas: Digestate:

Quebec2
Location: ProjectType: Capacity: Substrate: b Industrialpark PPP(66%public,34%Private) 80to90000t/yr SSO Agrifoodresidues Commercial,Institutionalresidues H2Sremoval,usedinethanolplant Mechanicaldewatering g Liquidandsolidfertilizer UF/ROtreatment
8

Biogas: Digestate: g

ProjectsEngineered(Ontraio)

HarvestPowerMustangRaptorProject,LondonON
Location: ProjectType: Capacity: Substrate: LondonON Private 60to75000t/yr CoFeed DAF,Marketwaste,KitchenWaste,aerobic Sludge CombustedinCHPtogenerateElectricity Mechanicaldewatering Solidfertilizer

Biogas: Digestate:

HarvestPowerMustangRaptorProject,LondonON (AnotherView)

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RAPTOR

TM

RAPID RAPID TRANSFORMATION OF OF ORGANIC RESIDUES

RAPTORTM

RAPTORTM FEATURES
1. Efficientandrapidconversionof organic residuestobiogas

RAPTORTM SUBSTRATES
1. 2. 3. 4. Energycrops,Corn(silage),VariousGrasses,Algae Agricultureresidues Marketsurplus,kitchenwaste,restaurantwaste Market surplus, kitchen waste, restaurant waste Offspecfruit&vegetables,Excessharvest (tomatoes,) Agroindustryresidues: Beetpulp,Tapiocapulp Vegetable/potatowaste V t bl / t t t Fat, Oil&Grease,DAF,CDAF Blood&otherwastesfromrenderingplants. Industrialresidues Brewerywaste Fruitprocessingwastes Papermillsludge

2.

3. 3 4.

5. 6.

Diversepretreatment totreatcomplexorganic matter 5. 6. Lowresidueproduction L id d ti 7. 7 8. 9. Accurate,labtestedandcomputeraided processdesign Continuous,easyandpractical operation Flexibleprocess,easilyadaptablefor new substrates bt t

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Pretreatmentstoincreasespeedandyieldofanaerobicdigestion process
Enzymatic forcellulosic/hemicellulosicsubstances Chemical mildcaustictreatmentforpolysaccharides/proteins Thermal slurryheatingforanimalproducts,proteins/fats Thermal slurry heating for animal products proteins/fats Mechanical particlesizereduction;finemashing Biological ThermophilicAcidificationReactor(TAR)

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ORGANICRESIDUES

PULP&PEELS PULP & PEELS MUNICIPALSOLID WASTE

ORGANICFRACTIONOFMSW RESTAURANTWASTES SUPERMARKETWASTES GREASE TAPIOCAINDUSTRY BANANA PINEAPPLE POTATO

ENERGYCROPS
CORN GRASSES STARCH

MANURES
PIG,DAIRYCOW POULTRY

SLURRIES
MUNICIPALSLUDGE INDUSTRIALWASTES FOODINDUSTRY SLAUGHTERHOUSE FOG,DAF FLOAT

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Samples

Economicalevaluationofthemix(feedsubstrates)
AdditionalRevenue i. Risk i. Technical,Legal&Safetychallenges

ii. Cofeedormainfeed iii. Quantity&Quality Seasonal,RegularORSpotopportunity iv. Processing ii. Gain i. TipFee onreception&processing ii. Additionalenergy canyouexportthat? ii Additi l t th t? iii. Additionalfertilizer Impactionfertilizerquality? iv. Possibilitytosubstituteanyothersubstrate comingfromlonger iv Possibility to substitute any other substrate coming from longer distance,lowenergyandmoreimpurities

Economicalevaluationofthemix(feedsubstrates)
Additionalrequirements

1. 2. 3.

Technicalequipment, Contaminantremoval Homogenization,mixing,hygienization andstorage

Impacton

1. 1 2. 3. 3 4.

Nutrientbalance N t i tb l Digestate quality Quantity&dewateringabilityofresidualsolids Quantity & dewatering ability of residual solids Processeconomics

SubstrateClassification

1. Protein[C4H6ON] i h 1 P i [C ON]richwaste 2. Fat[C15H31COOH]richwaste 3. Carbohydrate[C6H12O6]richwaste

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SubstrateClassification

TypeofSubstrate Protein Fat Carbohydrate Cattleslurry Cattle slurry

VSReduction 75% 90% 50% 50%

BiogasProduction (lperkgVS) 700 1250 747 350

CH4inthegas 71% 68% 50% 62%

FromJewell&McCartyworkin1960sand1970s

Biogasyieldsfromplantconstituents(Braun2007)andslurries(Baserga 1998).

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Study FeedMixture(Recipe)developmentforCoDigestionDigesters
Sponsoredby Sponsored by

Doneat

Studyplandevelopmentandtrialsupervision

AshwaniKumar,P.Eng. , g

Substrate&Recipetesting

1. 1 2. 3. 4.

Analytical(Physical&Chemicalcharacterization) A l ti l (Ph i l & Ch i l h t i ti ) BioMethanePotential(250mlreagentbottles) BenchScaletesting(8Lto20L) PilotTesting(300L)

PilotUnit Theconcept

Capacity 200LitWorking+100LitGasHolderVolume

GasSpace

LiquidSpace

FeedingFunnel Pressure P Measurement

TemperatureMeasurement Temperature Measurement

GasFlowmeter

BasisofRecipeDesign:
1. Watersolubilityoftheorganics

2.SpecificNutrientratiossuchas OptimizedC:NratioandC:N:P:Sratio

3.Consistentfeedavailabilitythroughouttheyear.

4.AvoidthetoxicityinfeedmixtureonaccountofPhytochemicals,Azo d d h f d f h h l dyes, Surfactants,Aliphaticcompounds,Aromaticcompounds,Salts(eg.Na+,K+,Ca2+), Heavymetals,Ammonia,InorganicScompounds,Proteins&Aminoacids, y , , g p , , Formaldehyde,Cyanide(CN)etc.

5.Optimizedbiogasyieldbyselectingtherightmixoffat,proteinsandlipids.

Technicaloptimizationofthemix(feedsubstrates)

1. Differentmixtureformulation(recipe)isdonewithpreliminarydesktopreview basedonsubstrateavailabilityintheregionandpracticalfieldfeedback. 2. Theproposedrecipeisvalidatedandtweakedbasedontherecommendation ofthetechnologyprovider/experts. of the technology provider/experts. 3. Allindividualsubstratesaretestedforphysicalandchemicalpropertiesand arethendigestedtogetthebiomethanepotential(BMP)togetCH4yield/Kg ofVSfeed. 4. Recipeisdigestedina20litre benchscaledigestertooptimizethedigestion processandunderstandspecificrequirementsrelatedtotheparticularrecipe. process and nderstand specific req irements related to the partic lar recipe 5. Theprocessistransferredtothe200Litre pilotunittovalidatethedesign assumptions.

Organic Loading Rate (OLR) (as Kg VS/M3 of Digester/day)

4.50

4.00

3.50

3.00

2.50

2.00

1.50

1.00

0.50

0.00 28May 2Jun 7Jun 12Jun 17Jun 22Jun 27Jun 2Jul 7Jul 12Jul 17Jul 22Jul 27Jul 1Aug 6Aug 11Aug

100

200

300

400

500

600

700

800

900

0 28May09 30May09 1Jun09 3Jun09 5Jun09 7Jun09 9Jun09 11Jun09 13Jun09 15Jun09 17Jun09 19Jun09 21Jun09 23Jun09 25Jun09 27Jun09 29Jun09 1Jul09 3Jul09 5Jul09 7Jul09 9Jul09 11Jul09 13Jul09 15Jul09 17Jul09 19Jul09 21Jul09 23Jul09 25Jul09 27Jul09 29Jul09 31Jul09 2Aug09 4Aug09 6Aug09 8Aug09 10Aug09 12Aug09

Biogas Production [Liter/day]

Proteinrichwaste a. a Theyarebiologicalmacromolecules eithersolid(eg.hair,nails,feathers They are biological macromolecules either solid (eg hair nails feathers YoudontwanttobringthemtoyourAD)orsoluble. b. UnlikeCarbohydratehydrolysisthatfavours slightacidpH,Proteinhydrolysis requireaneutralorweeklyalkalinepH(McInerney 1988) c. UnlikeCarbohydrateFermentationthatlowerthepHduetoformationofVFA, fermentationofaminoacidsdonotleadtosignigicat changeinpHduetoacid andammoniaformation. d. Butmostimportantforprocess&operationis watchoutfor

Sulphur
29

&Nitrogen

MixerFailure MixerFailure Mixer Failure

SolidSeparationTrials

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SolidSeparationTrials Th.designvs.Actual

Sl.#

Parameter
Suspendedsolids separationefficiency Suspendedsolidsin thefiltrate the filtrate Polymer ConsumptionNorm

Actual Performance
99+%

Comments
Thiswas repeatedon72literpilot testingusing100meshwinepress testing using 100 mesh wine press test

170mg/l 350g/m3
(13.4Kg/T S)

FerricSulphate Norm

1574g/m3

This isnotrequiredtomeetthe requirements,butithelpedin reducingtheturbidity reducing the turbidity

Digestate analysis

Parameter

(PhaseI) MaytoNov2009

(PhaseII) Nov2009toMay 2010 1490

(PhaseIII) StabilizedDigestate

BOD,mg/l

516

Totalsolids,mg/l

170

6550

42047

3 4 5

Phosphorous, total, Phosphorous total mg/l TKN,mg/l AmmoniaN,mg/l

6.22 2190 1390

86.7 1830 1050 5100 3510

Ammonia Vs TIme

5.0

4000

4.5 3500 4.0 3000 Org ganic Loading (k VS/cu m) kg 3.5 Ammonia (mg/ /kg) 2500 3.0

2.5

2000

2.0 1500 1.5 1000 1.0 500 0.5

0.0 5/28/2009 6/28/2009 7/28/2009 8/28/2009 9/28/2009 TIme 10/28/2009 11/28/2009 12/28/2009

0 1/28/2010

Organic Loading Rate Self Calulating Kg VS/M3

Ammonia mg/kg

Waste Nodefinitiveboundary

Sample

Ash

Carbohydrates

Protein

Fat

Total Nitrogen

Ammonia

Blood

1.27%

7.98%

3.45%

2.00%

0.48%

765

Manure

0.76%

0.20%

17.49%

0.20%

0.44%

1980

ThereisnoBlackorWhiteSubstrate

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Conclusion Recipe (Physio Chemicalchecks) a. Checkforavailability&handling b. Takearepresentativesampleanddo(oraskfor)sometests c. Ch k f N i CheckforNutrientBalance B l a. COD:N:P of350to100:7:1 b. RightC:Nofthemix(around20:1) d. Check for Toxicity (Antibiotics, Cation, Na+, Ammonia, Sulphides) , CheckforToxicity(Antibiotics,Cation,Na+,Ammonia,Sulphides), e. Checkforchemicalprecipitation(Calcium,Struvite)risks. f. Checkforheavymetals youdonotwantyourbiosolidstobeuntouchable
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Conclusion Recipe (Physio Chemicalchecks) g. Checkforprocessstability h. Temperature. pH H Noofstagesetc.

Dosomelab/pilotscaletrialsbeforeexperimentingonthefullscaleplantto reducerisks. reduce risks.

i. j.

IftimeiscriticalthenminimumperformATA(anaerobictoxicityassay)test. Ensuretrailsaredonelongenoughtoachievestabilizedoperationtoget realisticresults.

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ThankYou

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