BioPV - ORGANIC WASTE-PRESS WATER DIGESTION
GESCHER, GERMANY

Customer: Entsorgungsgesellschaft Westmünsterland mbH (EGW) Gescher, Germany
Leadtime: 2012 - 2014
Investor/Operator: Entsorgungsgesellschaft Westmünsterland mbH (EGW) Gescher, Germany
Throughput: 60,000 Mg/a
Scope of work: Development and conception of an alternative fermentation process to improve the energy balance and processing capacity of composting plants. Construction, production, completion, installation and commissioning after trial operation.
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BIOPV - BIOLOGICAL AND RESIDUALS PRESS WATER FERMENTATION

In close cooperation with the Entsorgungs-Gesellschaft Westmünsterland (EGW) and the Department of Urban Water and Waste Management at the University of Duisburg-Essen, Sutco RecyclingTechnik developed the Biological And Residuals Press Water Fermentation (BioPV) process, which combines composting with biogas production.
After intensive studies
, the practical implementation also proves the increased efficiency of the process in everyday life.
The Gescher composting plant at EGW was converted for this purpose. This process took about four weeks and was carried out extensively during operation. A miniaturized overall plant was built on a laboratory scale at the University of Duisburg-Essen. These investigations serve to further optimize the process and to record it qualitatively and quantitatively more quickly.

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ADVANTAGES TO COMMON PROCEDURES

Looking at common composting processes, energy is mainly consumed for the necessary mechanical aeration. In the newly developed process, the liquid, organic components of the biowaste are separated in advance and used for biogas production. In this way, energy can also be generated in the plants. A new biofilm fermenter was designed for the project, which has cost advantages over other fermentation processes. In this way, the process improves the energy balance and the processing capacities of composting plants.

DISPOSE AND PRODUCE

In the BioPV process, a screw press separates organic components. This separates organic components from the pre-treated fresh organic waste. The solid portion removed by organic matter is fed into the conventional composting process. This preliminary stage of pressing creates additional treatment capacity and enables the plants to process more material with their existing equipment. The specific energy consumption per ton of biowaste is reduced by 10 to 15 %.

RESIDUAL WASTE < 80 MM + WATER [Mg] PRESS WATER VOLUME PRODUCED [m³] DWELL TIME DIGESTION PLANT [d] BIOGAS [m³] FOR EACH TON OF PRESS WATER BIOGAS [m³] FOR EACH TON OF ORGANIC
100 + 60 60 8 - 10 90 54
PRESSING EQUIPMENT FOR RESIDUAL WASTE AND THE DIGESTION OF PRESS WATER QUANTITIES PROFITABILITY
Estimated investment costs 60,000 Mg of residual waste
< 80mm / a
~3,5 Mio €
Estimated wearing and operating costs Incl. presses and BHPP ~200,000 € / a
Estimated energy consumption ~190,000 kWh / a ~30,000 € / a
Estimated energy generation with a CH4 content of 60% in a CHP plant 3,240,000 m ³ / a -> 9,200.000 kWh el / a ~100,000 € / a (0,12 €/kWh el)
Information provided without guarantee
ORGANIC WASTE [ Mg ] PRESS WATER VOLUME PRODUCED [ m ³ ] DWELL TIME DIGESTION PLANT [ d ] BIOGAS [ m ³ ] JE Mg PRESSWASSER BIOGAS [ m ³ ] JE Mg BIOABFALL
100 + 75 75 8 - 10 55 42
PRESSING EQUIPMENT FOR ORGANIC WASTE AND THE DIGESTION OF PRESS WATER QUANTITIES PROFITABILITY
Estimated investment costs 60,000 Mg of organic waste/a ~3.2 Mio €
Estimated wearing and operating costs Incl. presses and BHPP ~200,000 € / a
Estimated energy consumption ~190,000 kWh/a ~30,000 € / a
Biogas produced and energy production in CHP unit 2,500,000 m ³ / a -> 7,000,000 kWh el / a ~980,000 € / a (base EEG 2016)
Revenues of each ton of digestion input 15,000 – 30,000 Mg / a 2 bis 5 € / Mg
Information provided without guarantee

BIOGAS FROM BIOWASTE

The pressed liquid is treated in a new fermentation plant and biogas is produced in the fermenters. The gas in turn can be used in engines to generate electricity and heat or fed into the natural gas grid as biomethane. This means that biogas can be produced in part from biowaste instead of from renewable resources. A plant with 60,000 t/a produces around 15 million m³ of biogas per year. With a methane content of 60 to 65%, this corresponds to around 9 million m³ of natural gas.

 

OVERVIEW OF THE ADVANTAGES

  • Fermentation of a highly energetic liquid phase, recovered from the solid waste in the bypas to the compositing process
  • Removal of easily available organic material from the solid waste: to facilitate the aerobic treatment
  • Simple fermentation system of modular design with low investment costs
  • High throughputs and low dwell times in a fixed-bed fermenter with a fixed bacterial colonisation
  • Very high methane content of 60 - 70% and thus a high energy content in the biogas
  • Circulation of the fermentation residue for wetting the fresh biowaste; no waste water to be disposed of externally
  • Low-wear plant equipment which is easy to operate and maintain
  • Automatic sand separation in the current fermentation process
  • Hygienization by thermophile and continuous fermenter flow possible
DOWNLOAD REFERENCE-PDF
Digestion of aliquid phase pressed out of organic waste in biofilm reactors