UTS Biogastechnik GmbH - Technological solutions for production of biogas practical examples
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UTS Biogastechnik GmbH
Technological solutions for
production of biogas
practical examples
UTS presentation at the
Simon Ford
Presentation Content
1. Company Background
2. Economical preconditions and environmental aspects
3. Technological solutions for production of biogas from
biodegradable municipal and industrial waste, manure,
sewage sludge
4. possibilities for utilization of residues
Topic 1: Company background UTS
Company Background
Established in 1992
as U.T.S. Umwelt-Technik-Sued GmbH
Formation in 2007 as
UTS Biogastechnik GmbH
(Universal Technology Services for Biogas)
Unmatched experience from > 1,500 plants with multiple feed-stocks
Active in several European countries
(Germany, Spain, Italy, Czech Republic, Hungary, Austria, Great
Britain, Netherlands etc.)
Multiple international patents on technologies and components, all
designed to make for highly reliable plants
1: UTS Portfolio
Turn-key supply of biogas plants
Design, planning/engineering, execution/errection,
components, turn-key solutions
Technology for manure and waste handling
Pumps, hydraulic/electronic mixers, piping, assecories
Substrate dosing equipment
Separation technology
Electronic process control with remote monitoring
capabilities
Biological support
Spare parts / technical service
Concepts for financing and insurance
1: UTS Biogas Plants
Topic 2: economical /environmental aspects Regulations Substrates Size Energetic use of biogas
2: Regulations / Economic Drivers Approx. feed-in tariffs for ~ 500 kW el
2: Regulations / Economic Drivers Energy (electricity, heat, biogas, biomethane) Funds/grants Tip fees for waste streams / reduction of waste Reduction of smell CO2 certificates Generation of „bio fertilizer“ and high value products
2: Regulations / waste management
Are the inputs wastes or products? (EU waste
regulations and local implementation, EU codes)
Are waste management licences necessary?
What treatements are allowed (slaughterhouse
waste CAT 1, 2, 3)
2: Regulations / waste management Commercial impact of waste to biogas: Pasteurization (70 °C I hour) or higher (e.g. 130 °C) Reception halls with air management systems (e.g. biofilter) Separation technology (mechanical, thermal) to take out contaminants Dewatering for low dry solids inputs Ammonia stripping for inputs with too high nitrogen Legal requirements connected with accepting digestate: are farmers willing to accept? More regulations with storage of digestate? Investment costs as well as operational costs and energetic costs of the above processes?
2: Different Feedstocks = Different Yields
Electricity Production in kWh/t Fresh Material
Corn silage
Pig manure
Cow manure Stillage
Slaughterhouse Organic waste
waste3: Typical 500 kW Standard Concept
F1
RP FS
F23: technological solutions
Examples of 500 kW el Designs
Germany:
15 t/d of cow slurry + 27.5 t/d of corn silage
(total input of 42.5 t/d)
Czech Republic:
50 t/d of cow slurry + 55 t/d of cow manure +
5 t/d of corn silage
(total input of 110 t/d)
Spain/France:
50 t/d of cow slurry + 20 t/d of food waste+
15 t/d of flotate sludge
(total input of 85 t/d)3: Energy Production at 500 kW
Biogas
~ 5,740 m³/d @ 55% CH4 (CZ example)
=> ~ 10.4 Mio kWh/a
Electricity
Gross value ~ 4.00 Mio kWh/a (~ 38-39%)
Thermal
Gross value ~ 4.48 Mio kWh/a (~ 40-43%)3: Digestate of 500 kW el Designs
Germany:
15 t/d of cow slurry + 27.5 t/d of corn silage
(total input of 42.5 t/d) => 35 t/d of digestate
Czech Republic:
50 t/d of cow slurry + 55 t/d of cow manure +
5 t/d of corn silage
(total input of 110 t/d) => 103.1 t/d of digestate
Spain/France:
50 t/d of cow slurry + 20 t/d of food waste+
15 t/d of flotate sludge
(total input of 85 t/d) => 78.8 t/d of digestate3: Operation / Maintenance
Air tight tank
Acid-forming Methane-forming
bacteria bacteria
Org. material Decomposition of org. material
Retention time ~ 10 – 60 days3: Balance
Acid-forming bacteria
- pH value 4 – 5
- T > 8°C
- generation cycle 4 – 5 days
Methane-forming bacteria
- pH value 7.4 – 8
- T ~ 35 – 45°C (mesophilic),
~ 52 – 55°C (thermophilic)
- generation cycle 10 – 14 days3: Parameters to monitor - Input
Quantity of substrate(s)
Quality of substrate(s)
- dry matter
- organic dry matter
- particle size
- NPK
- absence of glass, metal, moulds etc.3: Parameters to monitor – Fermentation
pH value
NH4-N in kg N / m³
Buffer capacity FOS/TAC
FOS = volatile organic acids
TAC = total anorganic carbon
Dry matter3: Parameters to monitor - Output
Concentration of CH4, CO2, (H2), O2 and H2S in
gas
Comparison of substrate feeding versus
performance (electricity production)
Goal: Input Energy = Output Energy
(if input energy > ouput energy => increase of acid
concentration)3: How to arrive at the Input Value
Measurement?
Calculation!
- vendor-specific
- neutral basis
E.g. KTBL
http://daten.ktbl.de/biogas/startseite.do#start3: References: Blümel-Teugn, Germany Plant size 520 kW Substrates 13,000 t/a green and brown bin Owner Blümel Regenerative Energien GmbH Start 1994/5 Comments UTS provided pump technology to pump substrates into fermenters Next to waste plant, UTS has built a 714 kW energy crop plant
3: References: Eggertshofen, Germany Plant size 890 kW Substrates fats/grease, food waste, vegetable/fruit wastes, sludges, whey Owner Josef Pellmeyer Start 1997 Comments Next to waste plant, UTS has built a 680 kW energy crop plant
Mantoagricoltura, Italy
3: References: Igel-Heiligenstadt, Germany
Plant size 60 kW
Substrates bread and bakery wastes
Owner Igel
Comments
Design from Hochreiter
Plant technology from UTS.
Possible expansion to 120 kW3: References: Langenwetzendorf, Germany
Plant size 3000 kW
Substrates 180 m³/d of pig manure
40 t/d of chicken manure
50 t/d of corn silage
6 t/d of grains
Start 2007
Owner Mr. Ölsner
Comments
Chicken manure is brought in from
the Netherlands3: References: Pfisterer, Germany
Plant size 300 kW
Substrates ~ 5 - 10 m³/d Food Waste
~ 2 m³/ d Market Disposal
Owner Pfisterer
Comments
Design by a local engineer office
and UTS
SCADA, pumps and feeding unit
by UTS3: References: Kloh, Germany Plant size 2 x 500 kW Substrates 18.000 tonnes a year of different kinds of source segregated C & I wastes. Owner Kloh Food Waste Comments Plant that has been extended numerous times over the years. Another plant is in the planning
3: References: Greiml, Germany
Plant size 1000 kW
Substrates Food scraps, fats, slaughterhouse
waste, maize silage
Start 2002-2006
Owner Mr. Greiml3: References: Unzanotti, Italy
Plant size 1000 kW
Substrates Various solid and liquid wastes, potato
wastes, sugar beet pulp.
Start 2004-2006
Comments
4 Fermenters and 2 secondary
fermenters3: References: Bianchi, Italy
Plant size 1052 kW
Substrates Cattle slurry, slaughterhouse
waste, silages
Start 20073: References: BIOWATT GmbH, Italy
Plant size 940 kW
Substrates Cattle slurry and manure, apple
processing waste, industrial, commercial &
agricultural wastes
Start 2002
Comments
First jointly owned
biogas in Italy.3: References: Cascina Guazzina, Italy
Plant size 955 kW
Location (Borgo San Giovanni (LO))
Substrates Pig slurry, silages, tomato pulp,
sugar beet pulp, rice chaff
Start 20033: References: Az. Agr. Campone , Italy
Plant size 2200 kW
Location (Costa De Nobili (PV))
Substrates Tomato pulp, silages, industrial and
agricultural wastes, pig slurry
Start 2004
Comments
Biggest biogas plant in Italy when it
was built3: References: Mantovagricoltura, Italy
Plant size 1 MW
Substrates 15 – 30 m³/d of slaughterhouse wastes
10 – 15 m³/d of energy crops
Owner Mantovagricoltura
Comments
Expansion to 2 MW in 2008/9Topic 4: Utilization of residues Fundamental issues: Hygeine: potential pathogens and spreading of these if inputs come from different farms. Volume/mass is similar (70-95% of input): logistics to spread to land: pumpability and residues: need for separation Temperature when spreading using technology to limit nitrogen loss (irrigation systems, umbilical systems) Lack of legal regulations regarding what to do with digestate
4: Purification, concentration of residues
Low Solid Screw Presses
High Solid Screw Presses
Hydro-Cyclones
Dissolved Air Flotation Systems
Biomass Flotation Systems
Pre-Composting Drum4: Low Solid Screw Presses
4: Low Solid Screw Presses
filter screw presses for separating and thickening of low and high
concentrated suspensions and sludges, such as manure, digestate,
distiller´s wash and waste water
dry matter content can be increased from4: Low Solid Screw Presses
Features:
gear motor drives from 4.0 to 11.0 kW
wedge wire screens with slot sizes of 0.25 to 1.0 mm
auger with hard-coated and precisely grinded flights
housing made of cast iron, all fluid contacting parts made of stainless
steelLow Solid Screw Press 3D-Animation
4: High Solid Screw Presses
4: High Solid Screw Presses
screw presses for compacting and further dewatering of pre-
thickened suspensions and solids
dry matter content can be increased from 15-30 % to 40-60 %
Functional principle:
wet material is pre-dewatered by a lamella grid in the inlet housing
screw conveys pre-dewatered material into a slotted pipe
material is pressed against a solid plug at the discharge end
water drains through a stable slot screen in the pressure area4: High Solid Screw Presses
Features:
compact design
different versions with single and double screw
gear motor drive, from 7.5 kW
screen, lamella grid and slot pipe made of stainless steel
high wear resistance (screw and other wear intensive parts are
special hard coated)High Solid Screw Press 3D-Animation
4: Hydro-Cyclones
4: Hydro-Cyclones
effective centrifugal separation of sand and other specific heavy
particles from waste water flows
Functional principle:
waste water is pumped tangential into the cylindrical feed chamber of
the cyclone and gets into fast rotation
larger or denser particles are transported to the wall by centrifugal
forces, move downwards in the conical part of the cyclone and leave
the unit via underflow outlet
clarified liquid and finer or less dense particles flow upwards in the
centre of the cyclone and exit via an overflow pipe4: Hydro-Cyclones
Features:
nearly all particles above a defined particle diameter can be
separated (depends on diameter of the feed chamber)
pressure drop of approx. 1 bar
very compact design, easy installation
no moving parts, no maintenance4: Hydro-Cyclones
Hydro- Cyclone 3D-Animation
4: Dissolved Air Flotation Systems
4: Dissolved Air Flotation Systems
dissolved air flotation systems for separation of floatables and
suspended particles from waste water flows
Functional principle:
air is dissolved in water by a multistage pump under pressure,
afterwards microbubbles are generated by relieving pressure
microbubbles adhere to suspended particles and float them to the
water surface
solids are removed at the surface by a skimming device4: Dissolved Air Flotation Systems
Features:
a part of clarified water is recycled, saturated with air and mixed with
the waste water flow before feeding to the tank again
feed water is dosed with a coagulant (such as ferric chloride or
aluminum sulfate) to flocculate the suspended matter
compact units, complete available with micro-bubble generator,
coagulator and coagulant dosing stationDissolved Air Flotation 3D-Animation
4: Biomass Flotation Systems
4: Biomass Flotation Systems
closed gas flotation systems (patent pending in US) for separation of
anaerobic biomass (after separation with low solid screw press) for
recirculation to the digester
recirculation of sludge increases solid retention time for improved
methane production
increased sludge load improves decomposition of organic matter
Functional principle:
a part of clarified liquid is recycled, saturated with biogas (instead of
air) and mixed with the separated digestate before feeding to the
tank4: Biomass Flotation Systems
liquid is injected to flotation cell tangential at 4 different positions and
causes the mass to spin
lighter float moves to the centre of the cell where it is harvested by
overflowing a vertical weir
clarified liquid exits at the bottom of the floatation cell4: Biomass Flotation Systems
Result of flotation process:
pre-separated digestate from low solid screw press is fed to the
floatation cell with around 5 % solids
approx. 95 - 98% of total suspended solids (TSS) and approx. 90%
of Phosphorous of digestate is removed in line with the low solid
press (need of polymer)
floatation sludge is a concentrated suspension with 8-10 % solids,
rich in Phosphorous
clear run of the flotation cell contains only 0.5 – 0.75 % solids (TSS)4: Biomass Flotation Systems
Digestate
Digester
Solids
Floatation Screw
sludge
Polymer press
Flotation
Separated
Cell digestate
Biogas
Multiphase
pump
Clear RunBiomass Flotation System 3D-Animation
4: Pre-Composting Drum
4: Pre-Composting Drum
unit to produce and recycle cow comfortable bedding material
Functional principle:
separated and pre-dewatered cattle manure/used bedding
material is fed into a rotating, isolated drum (on the face side) by a
stuffing screw continuously
material rotates in the drum for approx. 24 hrs, before it is discharged
on the back side
temperature in the drum increases to 55-65°C by means of an
aerobic process
material is dry, semi-pasteurised and comfortable for the cow after
the process, could be used as bedding.Pre- Composting Drum 3D-Animation
Summary
Thorough planning is a necessity
Flexibility in design is a recommendation
(economic drivers change => substrates change)
Biological service for commissioning is a must
On-going biological service is a recommendation
Goal:
Reliability in Technology and Service
for a successful Operation4: Solar and CHP heat used to dry digestate
Reference UTS Biogas Plant at Gross Denkte in North Germany
(536 kW Deutz, 27 m³ maize silage per day, dry fermentation
Heat is used to dry sewage work effluent:
2.500 tonnes p.a. @ 3% dry solids
just 100 tonnes p.a. @ 80% dry solids!UTS Biogastechnik GmbH
Thank you very much for your attention!
Web: www.uts-biogas.com
Email: s.ford@uts-biogas.com
Tel: +49 (8082) 9305-0
Direct: +49 (8082) 9305-71
Mobile: +49 151 5381 3031You can also read
