Energy through Waste Management A Initiative

Energy through Waste Management
A
Initiative
Dipl.Ing. Walter Danner (Consultant)
Alexander Varghese – Programme Manager
Energy and Cleaner Production Branch
Programme Development and Technical Cooperation Division
UNIDO, Vienna, Austria.
Energy through Waste Management – a UNIDO Initiative
Background of Walter Danner
Experience in
• MSW – organic waste digestion since 1995
• Own digestion plant
• DGS – head of biogas division (International Solar
Society German Section, www.dgs.de)
• Awards – Rottaler Modell
• Design of technology & equipment
- Sorting
- Mixer/Agitator
- Gasflare
• Research project – MSW Digestion in tropical countries
Energy through Waste Management – a UNIDO Initiative
Own Digestion plants – Rottaler Modell
DHS Stoffverwertungs GmbH
digestion plant / waste digestion
EAE GmbH
digestion plant / NAWARO
Energy through Waste Management – a UNIDO Initiative
Pilot-Digestion plant – Rottaler Modell in Thailand
Digestion plant / waste digestion in Thailand
Energy through Waste Management – a UNIDO Initiative
Background of Walter Danner –
Experience in India
• Biomass to Energy Seminar
• Ossein sludge digestion in Koratti
• Gasifier technology from India for Germany
• Test cultivation of energy corps in Kerala
Energy through Waste Management – a UNIDO Initiative
Digestion plant – Rottaler Modell in India
Test plant in India (sludge from Ossein plant)
Energy through Waste Management – a UNIDO Initiative
Test plant – gas production from sludge from Ossein plant
Pilot Plant (KCPL) Gas Production
20
1400
1. 30% sludge 750Kg loaded on 19/10/2002 & 6/11/02.
18
2. Daily feed 15 Kg of solid @ 13.6% Concentration.
1200
3. Carbon Dosage on 19/11/02.
16
12
800
10
600
8
6
400
4
200
2
Date
Gas Production, CM/T solid
Gas Production, CM/T (KCPL)
Gas Prodn. CM
20.12.2002
18.12.2002
16.12.2002
14.12.2002
12.12.2002
10.12.2002
08.12.2002
06.12.2002
04.12.2002
02.12.2002
30.11.2002
28.11.2002
26.11.2002
24.11.2002
22.11.2002
20.11.2002
18.11.2002
16.11.2002
14.11.2002
0
12.11.2002
0
Gas Output, CM
14
10.11.2002
Gas Output, CM/T of Solid
1000
Energy Potential
in the Various Types of Organic Waste
Energy through Waste Management – a UNIDO Initiative
Verfügbarkeit der Energie
8000
Biogas
7000
Kernenergie
Wind
2000
Strom aus Sonne
800
0
2000
4000
6000
Stunden pro Jahr
8000
10000
Energy through Waste Management – a UNIDO Initiative
Energy Comparison: Kitchenwaste / Petrol
10 kg Kitchenwaste
1,5 m3 Biogas
1 m3 Methane
1 l Diesel
10 km Car mileage
1 kg Biowaste = 1 km Car mileage
With the fermentation of the Biowaste from the Municipalities of Dingolfing-Landau and Rottal-Inn about
2.500.000 kWh Electricity is beeing produced equivalent to 10 Mio. km of automobile journey.
Energy through Waste Management – a UNIDO Initiative
Electricity output - Cofermentates
Electricity output
(in kWh per M.T.)
1.000
807
816
750
425
500
250
0
426
320
55
56
144
148
208
e
te
t
te
e
re
e
te
e
e
as
dg
st
ur
as
cu
ag
as
ur
nu
l
u
a
w
n
i
l
a
n
w
w
h
l
a
s
w
a
s
m
d
e
ss
oi
m
io
bl
ra
ge
ig
g.
Bu
em
oo
y
l
B
a
a
e
G
t
r
t
P
F
t
t
w
V
ge
ul
Ca
Se
Ve
Po
Energy through Waste Management – a UNIDO Initiative
Fluctuation in the specific yield of biogas from selected substrates for cofermentation (1)
Substrat
TS
%
oTS
%
Biogas
m3 CH4/kg TS
m3 CH4/kg/oTS
between to
between to
between
to
between to
Raw glycerine (RME man.)
Potato tops
Beet (turnip) tops
>98
25
15
90
79
78
93
0,62
0,40
0,19
0,67
0,47
0,40
0,69
0,50
0,24
0,72
0,60
0,50
Diverse cereals
Clover
Apple slop
85
20
2
89
0,26
0,32
0,30
0,53
0,40
0,30
0,40
0,33
0,60
0,50
15
85
80
90
Apple pomace
Spent grains from beer
Spent hops (dried)
25
20
97
22
97,5
86
87
90
0,22
0,45
0,63
0,50
0,25
0,50
0,70
0,55
Filtration silica gel (beer)
Vegetable waste
Old bread
Coco bean shells
Potato slop
Cereal slop
Foliage
Melasse
Whey
Fruit pomace
Oil seed residue (pressed)
30
5
90
95
12
6
0,02
0,18
0,67
0,02
0,30
0,24
0,70
0,35
0,40
0,75
0,22
0,52
0,33
0,29
0,50
0,24
0,60
0,40
0,30
0,48
0,27
0,58
0,55
80
4
45
92
18
90
25
15
15
95
6,3
76
96
91
90
87
82
95
80
93
97
80
95
90
90
98
90
0,74
92
0,25
0,56
0,48
0,60
0,60
0,52
0,62
Energy through Waste Management – a UNIDO Initiative
Fluctuation in the specific yield of biogas from selected substrates for cofermentation (2)
Substrat
Rape extraction residue
Grape pomace
Casto extraction residue
TS
oTS
Biogas
%
%
m3 CH4/kg TS
m3 CH4/kg/oTS
between to
between to
between
to
between to
88
40
90
93
80
81
0,24
0,59
0,26
0,63
98
0,20
0,64
0,36
0,65
90
0,05
0,54
0,18
0,60
Food waste (from large kitchens) 9
Vinasse
63
Organic waste (domestic)
30
50
40
75
55
53
30
95
Park and garden waste (fresh)
Clippings (sedge)
Blood meal
12
37
90
42
87
93
80
97
0,18
0,47
0,49
0,21
0,50
0,50
Flotation sludge
Stomach content (pigs)
Rumen contents (untreated)
Rumen contents (pressed)
Slaughter house waste
Fisch processing waste
Animal cadaver meal
Separator fat (gelatine prod.)
Fat (from fat separators)
Market waste
Residual waste
5
12
11
20
24
15
19
45
93
80
80
90
98
84
88
0,56
0,16
0,21
0,54
0,78
0,25
0,35
0,63
0,80
0,30
0,40
0,70
0,43
8
25
2
5
55
25
90
92
70
76
46
0,45
0,72
0,60
0,20
0,26
0,60
0,20
0,30
0,50
0,29
0,70
0,06
0,30
0,42
0,30
0,13
1,00
0,40
0,39
70
25
57
100
90
78
0,80
Basic Technologies
of Organic Waste Treatment
Basic Technologies
of Organic Waste Treatment
- Composting
- Digestion
- Gasification
Energy through Waste Management – a UNIDO Initiative
Comparison – Composting/Digestion/Gasification
Waste types as
Feedstock
Waste
Emissions
Characteristics
Waste from
Composting landscaping
MSW-organic fraction
<60 % moisture
structure material
like branches
Slaughterhouse waste
MSW organic fraction
Market waste
0-100 % moisture
liquid material
Digestion
Gasification
Pure waste fractions
like wood (chips)
Coconut shell
Coffee husk
Rice husk
<20 % moisture
solid material
Density > 180 kg/m3
Bad odour
Methane
Energy
Balance
Products
Investment
negative
Fertilizer
(less
nitrogen)
Low
No carbon
credits
positive
Biogas
Electricity
Heat
Cooling
Fertilizer
--
--
positive
Electricity
Heat
Cooling
Ash
High
High
Gasification
India is the world technology leader
We have an Indian gasifier in Germany
No need to talk about this technology
Energy through Waste Management – a UNIDO Initiative
Digestion
is a rather new technology
for MSW treatment in India
But very common in Germany
Energy through Waste Management – a UNIDO Initiative
Special Advantages of Anaerobic Digestion
Very wet waste can be digested – not possible by
composting
Slaughter house waste
Fat – flotation fat
Waste water
Liquid waste
Energy through Waste Management – a UNIDO Initiative
Advantages of Digestion
• No odour emission during the digestion process
• Possibility to control the process technically
• Energy output in the form of Biogas for generation of
electricity and heat
• Final digested material directly suitable for cultivation soil
reconditioner and fertilizer (pH 7)
Energy through Waste Management – a UNIDO Initiative
India has more biogas plants than Germany
But Indian biogas plants have a lower performance than
the German biogas systems
Energy through Waste Management – a UNIDO Initiative
Why do Indian biogas plants have such a low
performance?
The Indian digesters have no temperature controls
• No insulation against temperature losses + quick
temperature changes
• No heating system to keep the temperature on a
constant level
Energy through Waste Management – a UNIDO Initiative
Why do Indian biogas plants have such a low
performance?
The Indian experts think, that insulation is not
necessary, because it is already hot in India.
But:
• It is not hot enough for a stable digestion process
• India has day and night temperature changes
• India has temperature change by the seasons
Energy through Waste Management – a UNIDO Initiative
Temperature in the Digesters
Activity at T oC in %
Activity at 35 oC
150
Thermophilic digestion
100
Temperature: ~ 55 oC
50
Mesophilic digestion
Temperature: ~ 35 oC
20
30
40
50
60
o
C
Energy through Waste Management – a UNIDO Initiative
Digester with Insulation
Energy through Waste Management – a UNIDO Initiative
Insulation
Energy through Waste Management – a UNIDO Initiative
Heating System
Energy through Waste Management – a UNIDO Initiative
The Bottleneck of Digester Performance
Methane Bacteria
They are
• Sensitive on low temperature < 37°C
• Sensitive on temperature change
• Sensitive on low pH value < 7,0
• Sensitive on high organic load > 3,0 kg/m3/day
Energy through Waste Management – a UNIDO Initiative
Growing of anaerobic bacteria
Hydrolisis bacteria
1 – 24 h
12 – 36 h
to 48 h
Carbonhydrates
Protein
Fat
Acetogenic bacteria
9 - 12 h
12 - 18 h
Methanol and acetic acid
Lactic acid
Butter acid
Propion acid
Fatty acid
60 – 80 h
60 – 120 h
2 – 10 d
Methangenic bacteria
6 – 18 h
Various bacteria pedigree for producing H2
Various bacteria pedigree for producing H2
Various bacteria pedigree for producing acetic acid
Various bacteria pedigree for producing acetic acid
18 – 48 h
48 - 72 h
3–5d
24
48
72
96
120
240
h
1
2
3
4
5
10
d
Energy through Waste Management – a UNIDO Initiative
The Fertilizer – Problems in the Near Future I
Nitrogen:
- Produce from air with fossil energy (oil, natural gas) with 1 kg
oil per 1 kg nitrogen
ÆRising nitrogen prices caused by rising oil prices
ÆRising subsidies required (how long?)
Potassium:
- Fossil deposits
- In 10 years exhausted
Æ Rising prices
Energy through Waste Management – a UNIDO Initiative
The Fertilizer – Problem in the near Future II
Phosphorus:
- Fossil deposits
- High heavy metal conten in many deposits
Æ Rising prices
Solution: Closed Nutrient Loops
Energy through Waste Management – a UNIDO Initiative
Closed Nutrient Loop
Energy through Waste Management – a UNIDO Initiative
Fertilizer Analysis
Energy through Waste Management – a UNIDO Initiative
From MSW to the Best Fertilizer
All nutritients are still in the fertilizer; only the carbon
is utilized in the biogas
Clean fertilizer due to appropriate sorting technology
Free of toxic elements due to no shreddering of the
MSW
Complete hygienisation – free of bacterias, viruses
and seeds
Energy through Waste Management – a UNIDO Initiative
5-Step Sorting System for MSW – RM
Step 1
waste
hopper
Step 2
bag
opener
star wheel
sieve
Step 4
small
residues
fine screen
separator
small
fraction
55oC
37oC
hygienisation
digester
Step 3
big
fraction
sorting belt
wood
fraction
residues
Gravel, sand,
stones, bones,
cores, batteries
storage
tank
heavy
residues
Sand
fields
sieving
Step 5
residues
incineration
composting
Energy through Waste Management – a UNIDO Initiative
MSW Sorting
Energy through Waste Management – a UNIDO Initiative
MSW Anaerobic Digestion Technology
Receiving
Digestion
Sorting
Electricity Production
Biogas Production
Energy through Waste Management – a UNIDO Initiative
Effects of Sorting and Digestion
Sorting:
- Higher recycling rate
- Better working conditions for the less skilled
labour (scarvengers)
- Higher income for scarvengers
Digestion: - No odor emissions
- No methane emissions (green house effect)
Financing: - Carbon credits possible
Digestion of Municipal Solid Waste
Energy through Waste Management – a UNIDO Initiative
Comparison – Germany vs. India
Regarding Biomassproduction and Biogas
GERMANY
INDIA
Climate
For the biomass prod.
Temperature lower
Rain less
Seasons (spring, summer, autumn,
winter)
No winter
Æ Higher biomass production per
hectare possible
Experience in biogas
Big, hightec biogas plants with high
efficiency
Many small scale biogas plants for
small farms - Gobar System
Electricity price
Renewable engergy law
1992 Feeding to the grid Law
2000 Renewable Energy Act
2004 Renewable Energy Act
Market Price
Captive Power Price
Objectives
Electricity feeding to the public grid
Biogas for household use
Biomass production
~ 16 tons of DS/hectare per year
Prospect: 30 tons/hectare per year
> 50 tons of DS/hectare per year
possible
Cost
High labour costs
Low labour costs
Energy through Waste Management – a UNIDO Initiative
Feedstock Calculation
Feedstock
MSW
Quantity
5
tons
per day
1825
tons
per year
1,6
tons
per day
593
tons
per year
21
days
Organic fraction
65%
Sorting efficiency
50%
Sorted organic quantity
Retention time
Avoided disposal costs
417
Rs/ton
Transportation Calculation
Truck load
Costs per Truck
Costs per ton
6
tons/truck
2500
Rs
417
Rs
Energy through Waste Management – a UNIDO Initiative
Required Staff
per month
Manager
1
10.000
10.000
Technician
1
6.000
6.000
Supervisor
1
6.000
6.000
Hopper filler
1
5.000
5.000
Sorters
3
5.000
15.625
1
5.000
5.000
3
5.000
15.000
Sorting
200 kg/h
25 h
8 h/shift
3 sorters
Recycling material handling
Digester operator
3 shifts
62.625 per month
751.500 per year
Energy through Waste Management – a UNIDO Initiative
Economics
Revenue
Electricity sold
Avoided costs
Fertilizer sales
price/unit
in IRs
356 tons
4.000
IRS
Operating Costs
Biomass
Labour
Lubrication
Oil filters
Spare parts
Cogen
Equipment
Total
Capital Costs
Interest
Depriciation
Total
Total costs
0 tons
1
1
IRS
0
1650
200
5%
5%
Price
in IRs
751.555
247.135
1.423.500
2.422.190
0
751.500
1.650
200
12.500
5.750
771.600
12%
253.608
211.340
464.948
1.236.548
Gros profit/loss
1.185.642
Cash flow
Return on Investment
1.396.982
1,51
31%
10%
59%
30-40
60-70
0
Energy through Waste Management – a UNIDO Initiative
Summary & Comparison of MSW Sorting & Digestion Plants
Input per day in tons of MSW
Input per year in tons of MSW
5
1.825
Rs
Investment total
Investment per kW cogen capacity
Investment per ton of MSW per day
Investment per ton of MSW per year
Revenue
Electricity
Avoided disposal cost
Fertilizer sales
Total
2.113.400
47.553
422.680
3.563
751.555
247.135
1.423.500
2.422.190
Operating costs
Labour
Total
751.500
771.600
Capital costs
464.948
Profit
Cash flow
Return on investment in years
Installed capacity of cogeneration in kW
1.185.642
1.396.982
1,51
33
Energy through Waste Management – a UNIDO Initiative
Investment and Costs
Low cost investment due to indigenous equipment
First calculations show, that the investment only
1/5 of the investment in Germany
Low cost operation due to cheap labour in India
First calculations show, that the operating costs are
only 10 - 15% of the German costs
Energy through Waste Management – a UNIDO Initiative
Mixer
Energy through Waste Management – a UNIDO Initiative
Biogas Cleaning System – H2S-Removal
Energy through Waste Management – a UNIDO Initiative
Carbon Credits
Capacity / d
per ton of
MSW input
per day
5 tons/d
30 tons/d
100 tons/d
CO2 reduction by electricity
production
270 €
1.350 €
8.100 €
27.000 €
CH4 emission reduction in
comparison to landfill
5.783 €
28.900 €
173.490 €
578.000 €
-------
------
-------
-------
30.250 €
181.590 €
605.300 €
Chemical fertilizer replacement
Payment for carbon credits per year
Figures based on a preliminary calculation for a MSW digestion project in Hanoi/Vietnam adjusted
to Indian conditions.
Energy through Waste Management – a UNIDO Initiative
Implementation
• Investment determination
• Financing
- CDM – Cluster
• Pilot projects
• Capacity building:
- Engineering
- Operation
- Equipment manufacturing
Energy through Waste Management – a UNIDO Initiative
General Design Criteria
Heat Utilization
Power Generation
Type of Feedstock
Affordable Investment
Maintenance – Costs, Skills, Spare Parts Availability
Suitable to the Climate
Local Content
(Indigenous) – Equipment, Material, Labour
Transportation
Labour Costs
Size of the Market
Energy through Waste Management – a UNIDO Initiative
Thank you very much for your interest!