Andreas Weger

Folie 1 © Fraunhofer UMSICHT

Digestate management with the

TCR®-process – add-on for AD plants

ADBA R&D Forum 2015

14-15 April 2015 Southampton

Andreas Weger, Rolf Jung, Fabian Stenzel, Andreas Hornung

Fraunhofer UMSICHT, Institutsteil Sulzbach-Rosenberg

http://adbioresources.org/


Our motivation …

Energy conversion and storage

Raw and functional materials

© Fraunhofer

Agenda

Motivation

TCR®-process

Efficiency increase of AD plants

Digestate management

Conclusion


Motivation


Motivation

New challenges for AD plants in Germany

Amendment of the Renewable Energy Act (EEG 2014)

Upcoming amendment of the Fertiliser Ordinance

Recycling competition between manure and digestate

Efficiency increase possible through

Reduction of substrate quantity

Nitrogen removal in digestate (liquid phase)

Further value chain increase

Carbon-rich char valuable fertilizer (Taylor-made fertiliser)

Oil as possible fuel blend


TCR®-process


TCR®-process

Process description

Pyrolysis with integrated reformer unit

Temperature: 350 - 450 °C / 550 - 750 °C

Feed: organic residues from AD or bioethanol plants

TCR®-process converts organic residues into high-value products

Bio-Char (material or energetic usage)

Syngas/Oil (energetic usage)

Only solid digestate phase necessary

Fertilizer effect remains (liquid phase)

TCR®-

process


TCR®-process

Process scheme

Pre-treatment Fermentation

Biomass

Dewatering

Gas Digestate

.

Char

TCR® CHP

Power

Heat

Thermal drying

Oil

Digestate


TCR®-process

Elementary analysis and heating value (HHV)

Bio-Char Oil Syngas

C 55 wt.%

H 2 - 3 wt.%

N 0,5 - 5 wt.%

S 0,5 wt.%

O 20 wt.%

Ash 15 wt.%

HHV 22 MJ/kg

C 50 - 70 wt.%

H 8 - 10 wt.%

N 2 - 5 wt.%

S 0,5 - 2 wt.%

O 9 - 11 wt.%

Ash 0,2 wt.%

HHV 31 MJ/kg

H2 30 - 40 v/v%

CO2 20 - 30 v/v%

CO 10 - 20 v/v%

CH4 4 - 8 v/v%

CxHy 5 - 10 v/v%

HHV 14 MJ/kg


TCR®-process

Product yields




489 m³ i.N./h

AD plant 1 MWel

Substrate (Mix) 24.000 Mg/a

Operating hours 8.000 h/a

Biogas:

Gross Energy

20.426.412 kWh/a

Biogas 3.909.900 m³ i.N./a

489 m³ i.N./h

CH4-Yield 52,4 v/v%

CO2-Yield 47,6 v/v%

Heating value 5,22 kWh/m³ i.N.

Density 1,32 kg/m³ i.N.




Digestate

170 kg/h

85% DM

60 m³ i.N./h

TCR®

Syngas:

Gross Energy

1.872.661 kWh/a



Mix Gas:

Gross Energy

20.607.586 kWh/a


Reduction of substrate quantity ≥ 10% possible!

Substrate (Mix) 21.600 Mg/a

Operating hours 8.000 h/a

Biogas:

Gross Energy

18.734.925 kWh/a

Biogas 3.586.126 m³ i.N./a

448 m³ i.N./h

CH4-Yield 52,4 v/v%

CO2-Yield 47,6 v/v%



508 m³ i.N./h

AD plant 1 MWel


Separation

fester Gärrest

flüssiger Gärrest

Input

24.000 Mg/a

18.100 Mg/a

TS = 9,8%

5.030 Mg/a

TS = 25%

13.070 Mg/a

TS = 4%


Example nutrient balance

N P

6 2,5 kg/Mg

109 45 Mg/a

N P

4,5 3,6 kg/Mg

23 18 Mg/a

N P

6,6 2,1 kg/Mg

86 27 Mg/a

80% of nitrogen remains in the liquid phase [P as P2O5]

Solid phase

Liquid phase

Digestate

separation



Nitrogen removal

Output Char

N-enriched

Output liquid phase,

low nitrogen amount

Input liquid phase

Input Char


Conclusion


Conclusion

Can you get £100 per tonne from digestate?


Cost reduction ≈ 80.000 €/a in the case of energy crops (in Germany)

Nitrogen Removal

Lower demand of arable land, transport costs depends on situation

Bio-Char

Soil fertiliser (up to 600 € per tonne; Source: Sonnenerde.at)

Oil

Possible fuel blend


Thank you for your attention!

Contact:

Fraunhofer UMSICHT

Institutsteil Sulzbach-Rosenberg

An der Maxhütte 1

92237 Sulzbach-Rosenberg

E-Mail: info-suro[at]umsicht.fraunhofer.de

Internet: http://www.umsicht-suro.fraunhofer.de

M. Eng. Andreas Weger

Telefon: 09661-908-434

E-Mail: andreas.weger[at]umsicht.fraunhofer.de

Prof. Dr. Andreas Hornung

Telefon: 09661-908-403

E-Mail: andreas.hornung[at]umsicht.fraunhofer.de

Digestate management with the

TCR®-process – an add-on for AD plants

Andreas Weger

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