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FFE Solutions company presentation

MODERN BIOGAS PLANTS

Dipl.-Ing. Helmut Muche

FFE Solutions GmbH – Kolberger Straße 13 – 24589 Nortorf – Germanywww.farmatic.com

Jakarta - 11. October 2016

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FFE-Solutions company profileCompany history of 50 years

Annual turn-over approx. 15 - 20 Mio €

50 Employees

Headquarters in Nortorf (70 km North of Hamburg, Germany)

ISO certified quality management

Over 100 biogas plant references Over 100 wastewater treatment plant referencesOver 3,000 bolted steel tanks constructed worldwide

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Business Sectors

Biogas Plants Wastewater TreatmentTank and Storage

Solutions

Digestion Plants for organic Waste

Agricultural Biogas Plants

Engineering Services

Biogas

Agriculture

Energy Storage

Industry

SBR-Plants

Continuous Flow Plants

Equipment: Aerators, Mixers, Decanters

Thermal Energy Storage TES

Cold Water Storage

Hot Water Storage

PTH: Power-To-Heat

Industrial & Municipal WWTP

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We use bolted steel tanks for our biogas plants

Storage solutions with capacity up to 20,000 m³

Digesters up to 8,000 m³

Our modular design allows flexible solutions

Tanks can have any size and any width from 50 m³ - 20,000 m³

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Tank Construction on Site

silo bolt

PE cover

permanently elastic and

UV resistant sealant

Tank Interior Tank Exterior

glass coated steel panel 2 glass coated steel panel 1

No scaffolding necessary – tanks are built on the ground and then lifted by a special jack system.

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Digester Material

Liquid Zone Glass Coated Steel (GCS)Gas Zone Stainless Steel or GCS Roof Stainless Steel

Insulation and Sealant

10 – 20 cm of mineral woolPermanently elastic sealant (Sikaflex)

Operational Temperatures

Thermophilic 50° – 56° CMesophilic: 36° – 38° C

Watch the 3D animation on Youtube:

www.youtube.com/FarmaticAnlagenbau

Farmatic‘s signature – vertical constantly stirred digesters

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We use CSTR digesters for our biogas plants

• No sedimentation, no floating layers• constant substrate circulation

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Biogas

SubstratesSubstrates

Waste from the processing of vegetable raw materials and energy crops

Palm Oil MillEffluent

Spent wash

Empty fruitbunches

► Wastes from the processing of plants

► Energy crops

Napier grass

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INPUT PROCESS OUTPUT

PlantationFresh Fruit Bunch

FFB

Mineral fertilizer

Diesel

Crop protection products

Water

Solar energy

Palm Oil Mill

Products

Palm oil

Kernel

Power plantBoiler

Energy conversion

Water

Composting

Biogas plant

Compost Waste water

Emissions

Ash

PALM OIL PRODUCTION

Shells

Natural fertilizer

Biogas plant

Methane

Wood

OFB

Power plantGas engine

Grid

Water

Biogasupgrading

CNG

By-productsEmpty Fruit

Bunch Palm Oil

Mill Effluent Fibres Shells

Electricity

Steam

Decanter cake

Heat exchanger

Soil

Biogas

Compost

Waste water

Ash

Exhaust gas

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Separate anaerobic digestion of Empty Fruit Bunches and POME

Mechanicalsize reduction

DigesterV = 30,800 m³

EFB276 Mg/d

Biogas33,085 m³/d

Solid phase232 Mg/d19 % TS

Liquid phase695 m³/d

Composting

Fertilizer

60 Mg FFB/h

Dehydration

DigesterV = 7,336 m³

POME648 m³/d

Biogas19,790 m³/d

Effluent648 m³/d

Waste water treatment

648 m³/d

2015.11.19

Gas treatment

Power plant4,600 kW

Separation

Power plant1,800 kW

Power plant2,800 kW

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Comparison: CSTR digester – lagoon digester

Advantages

● simple design● high material quality● high volumetric load possible● High dry matter content possible

→ smaller digester volume needed● uses highly efficient vertical mixers● low energy consumption for mixing● External heat exchangers, easy maintenance● heat insulation

→ low heat loss● danger to groundwater easily eliminated● easy explosion protection● easy lightning protection● very low maintenance ● very long life span of the system● low overall life cycle cost● low footprint of facility

Continuous Stirred Tank Reactor Lagoon System

● simple design● easy access to construction materials

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Disadvantages

Lagoon System

● high initial investment cost● complex construction

● low material quality● only low volumetric load possible● only low dry matter content possible

→ larger digester volume necessary● low digester height results in very large

surface area→ bad mixing results→ high energy demand for mixing

● no heat insulation● groundwater protection difficult● entire facility is explosion hazard● lightning protection difficult● high running maintenance cost● very low life span● high overall life cycle cost● large footprint and land use


Continuous Stirred Tank Reactor

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Capital and operating costs


Lagoon System

Continuous Stirred Tank Reactor

Unit

Fresh Fruit Bunch 50 50 to/h

Volume flow POME 450 450 m³/d

Volume digester 22,000 5,400 m³

Hydraulic Retention Time ≈ 45 ≈ 11 d

Investment cost 685,000 790,000 €

Installed power agitators 18 30 kW

Energy consumption 130,000 170,000 kWh/y

Maintenance cost 116,000 3,400 €/y

Interruption 2 0 months

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FFE-Solutions GmbH · Kolberger Straße 13 · 24589 Nortorf

Telephone +49 43 92 / 91 77 - 0 · Fax +49 43 92 / 5864 · [email protected]

R E F E R E N C E S BIOGAS PLANT SKÖVDE, SEGöteborg Energi AB, Skövde, Sweden

Year of commissioning 2011

Gas yield 800 Nm³/h

Digester volume 2 x 4,350 m³

Post-digester volume 1 x 2,400 m³

Substrates:

Whey 71,000 t/a

Expired food 10,000 t/a

Slaughterhouse waste 8,000 t/a

Wastewater 7,000 t/a

Spoiled milk 3,000 t/a

Special Features

• Gas upgrading

• Thermophilic process (55°C) as pasteurisation

method

• Sophisticated heat management through heat

storage and recovery

• Very few pumps required, 80 % of the plant

operates through hydrostatic pressure

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R E F E R E N C E S BIOGAS PLANT LUSTENAU, ATHäusle GmbH, Lustenau, Austria


Gas yield 600 Nm³/h



Substrates:

Organic fraction of MSW 17,000 t/a

Cattle manure 5,000 t/a

Grease trap contents (fat) 2,000 t/a

Special Features

• Expansion of an existing dry fermentation

plant with a wet digestion line

• Hygienisation at 70 °C

• Sophisticated separation of solids,

impurities and other unwanted materials

by screw press and hydro cyclone

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R E F E R E N C E S BIOGAS PLANT ARAVETE, ESTAravete Biogas, Aravete, Ambla, Estonia


Installed power 2,000 kW



Substrates

Cow manure 63,000 t/a

Dry dung 25,000 t/a

Poultry manure 5,200 t/a

Gras silage 1,000 t/a

Brewery waste 8,000 t/a

Whey 4,000 t/a

Special Features

• Complex mix of substrates

• High dry matter content in some

substrates requires heavy duty cutting

and feeding machinery

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R E F E R E N C E S BIOGAS PLANT SØNDERJYSK, DKSønderjysk Biogas Bevtovt A/S, Vojens, Denmark

Year of commissioning 2016*

Gas yield 5,000 Nm³/h



Substrates:


Pig slurry 200,000 t/a

Straw 50,000 t/a

Sugar beet and pulp 50,000 t/a

Maize 15,000 t/a

Dry dung 10,000 t/a

Special Features

• Gas upgrading

• Thermophilic process (55°C) as

pasteurisation method

• Heat recovery from low temperature

return flow from gas upgrading facility

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R E F E R E N C E S BIOGAS PLANT SØNDERJYSK, DKSønderjysk Biogas Bevtovt A/S, Vojens, Denmark

Year of commissioning 2016*

Gas yield 5,000 Nm³/h



Substrates:


Pig slurry 200,000 t/a

Straw 50,000 t/a

Sugar beet and pulp 50,000 t/a

Maize 15,000 t/a

Dry dung 10,000 t/a

Special Features

• Gas upgrading

• Thermophilic process (55°C) as

pasteurisation method

• Heat recovery from low temperature

return flow from gas upgrading facility

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Thank you!

FFE-Solutions GmbH Kolberger Straße 13 · 24589 Nortorf

phone +49 43 92 / 91 77 - 0 · fax +49 43 92 / 5864 · [email protected]

Helmut MucheInternational Sales

[email protected]+ 49 176 11 2222 02 (Germany)+ 66 917160021 (Thailand)

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