design of anaerobic digestion facilities for recovering...
TRANSCRIPT
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Design of Anaerobic Digestion Facilities for Recovering Biogas
from Food Wastes
L.F. Diaz and G. M. SavageCalRecovery, Inc.Concord, California [email protected]
USCC 2009 Houston, Texas January 26 to 28, 2009
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Anaerobic Digestion• Introduction• Principles• Process rate limitation factors• Parameters• Operational considerations• AD Systems• Conclusions
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Introduction• Some mixed solid waste AD systems were
built during the 1970s and 1980s in the US
• Substantial operating problems and high costs resulted in plant closures
• In the US, AD generally competes with landfill disposal and composting, which tend to be less costly on a unit cost basis
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Introduction (cont.)• Thousands of AD plants have been built in
Europe during the last few years• Germany and Austria built some of the
first full-scale facilities in the 1980s• The technology has now been applied in
several other countries (i.e., Korea, Spain)• Overall installed capacity of AD facilities
treating the organic fraction of MSW in Europe is about 4 million tons per year
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Relevant Financial Incentives• Award “Green Certificates” (CG):
– European Directive 2001/77/CE– promotes production of energy from renewable sources– provides financial incentive to producer (time period and amount
vary from country to country)– one GC = 50 MWh of energy– in Italy, financial incentive is 0.115 €/kWhe per year (~0.138
US$/kWhe year)– in Italy, incentive is valid for 8 years from startup of plant – can
be extended 4 more years (financial incentive reduced to 60%)– in Germany, incentives last over 20 years
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Principles
DIGESTEROrganic Waste
Soil Conditioner
BiogasGreen Energy
1 m3 of Biogas at 60% CH46 kWh 600 kg CO2 emissions savings
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Two-stage representationORGANIC MATTER
VOLATILE FATTY ACIDS
Hydrolysis/Fermentation
Gasification
BIOGAS
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Design Awareness• Pre-processing of wastes is required to
produce:– an acceptable particle size distribution for
downstream equipment (AD feeding system, etc.)
– a “clean” feedstock (i.e., acceptable level of contamination)
• AD produces a biologically unstable process residue unless otherwise treated
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Design for Hostile Feedstocks
Need proper sizing and segregation of feedstock
Must invoke judicious selection ofequipment for processingand transporting slurry
Valve jammed withfiber and plastic
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Stability & Sustainability
• Overall, AD process rests uponmaintenance of a relatively critical balance
• Initially pH declines, then gradually rises –eventually, gas is produced
• End products: methane, carbon dioxide, other gases, and relatively stable residue
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Process Rate Limitation Factors• Availability of nutrients in waste• Cellulose converted into soluble
carbohydrates • Acid formers convert carbohydrates to
low-weight fatty acids• The final stage (methane formation) is the
slowest, and thus the rate-limiting one
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Physical Properties• Particle size• Moisture content• Chemical composition: C/N • Performance factors:
– transfer of metabolic products– elements or compounds
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Parameters• Gas production and composition:
– varies, depending upon substrate from 0.2 to 0.8 m3/kg of dry solids
– composition is about 50% methane
• Destruction of volatile matter:– varies from 30% to 80%
• pH:– generally within narrow range: 6.5 to 7.5
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Operational Considerations
• Mixing and formation of scum• Loading: measured in kg of VS/m3-day• Detention time: from 15 to 30 days, has
impact on volume of reactor• Starting a digester: culture
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Digester Construction Design Principles• Conventional• High-rate• Contact (fixed-bed)
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Conventional
• Low solids concentration• Dimensions depend upon total amount of
waste that must be treated• Gas production impacted by many factors
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Conventional Digestion (low solids)
Raw Sludge
Gas
Scum
Supernatant
ActivelyDigesting Sludge
Stabilized Sludge
Supernatant
Digester Gas
Digested Sludge
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High Rate
• Best suited for large-scale operations• Two-stage operation in series (each stage
takes place in a different digester)• First stage is active: thoroughly agitated,
short detention time• Second stage: material is not mixed,
serves as a settling chamber
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High-Rate Digestion (low solids)
RawSludge
HeatExchange
Gas
Active
Mixing
TransferSludge
Gas
Supernatant
DigestedSludge
DigesterGas
Supernatant
DigestedSludge
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Contact
• Popular version is the fixed-bed• Provide a surface upon which organisms
attach and form a film• Film is bathed by the waste • Film falls off periodically
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Modern Technologies
• Essentially divided as a function of total solids content in the reactor:– dry digestion: TS > 15%– wet digestion: TS < 12%
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Digester Heating
Several alternatives:– indirectly or directly– solar, fossil fuel, biogas
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Example of an installationfor the treatment of organic matter
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Areas for pre-treatmentand segregation
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Wet Digestion
DIGESTOR
GASOMETER
The electrical energy produced is used within the facility
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Metallic Digester
Digester made of steel. The main structure is made of galvanized steel, with adhesive stainless steel film inside. Photos on right shows the insulation; sheet metal (green) that protects the insulation; and the pipes for heating the digester.
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Digester Built Underground
Where possible, digesters are built below ground in order to achieve low heat losses. Solids are loaded by means of a hopper with a screw feed.
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Digester Feed Pump
Lobe type pump equipped with shredding unit. This is particularly useful in avoiding clogging in co-digestion.
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Method for Loading the Digester
Biomass is loaded into a hopper equipped with screws (Liquitech).
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Types of Reactor Mixers
Horizontal shaft with paddles (left, Hockreiter) propeller type with inclined shaft (right, Envicom).
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Dry Anaerobic Digestion
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Dry Anaerobic Digestion
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Dry Anaerobic Digestion
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Co-generation Equipment
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Range of Methane Production Obtained at Existing Facilities
Dry: T = 20 [d]; 10 [kg/m3d] : Vbiogas T = 3 m3/m3d : 300 m3/Mg/Dom= 10 [d]; 18 [kg/m3d] : Vbiogas = 3 m3/m3d : 167 m3/MgDom
Wet: T = 20 [d]; 2.5 [kg/m3d] : Vbiogas T = 1 m3/m3d : 400 m3/Mg/DomT = 10 [d]; 5 [kg/m3d] : Vbiogas = 1.6 m3/m3d : 320 m3/MgDom
Dom Volumetric Loading [kg/m3*d]
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Research in Pre-Processing of Organics
Research Comminutor and Monitoring Equipment
Close-up View of Cutters
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Lab-Scale Organic Fraction of MSW/Sludge Digesters in Richmond, California (1973)
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Pilot Food Waste Digester in Richmond, California (1984)
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Conclusions• Define quantities and characteristics of the
feedstock• Establish acceptable specifications for the
biogas and process residue• The implementation of separate collection
of food waste simplifies the design of facilities considerably--otherwise, careful pre-processing is needed
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Conclusions• Developing financially sustainable AD
systems in the US currently is a challenge given the alternatives
• Conditions in Europe favor development and implementation of AD systems