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Biogas Generation from Agricultural Wastes An Egyptian Experience in a Nile Delta Village (El Nenaiea) Eng. HASSAN GOMAA Environment & Renewable Energy Consultant-Egypt UNESCO-Africa Engineering Week with Africa Engineering Conference THEME: “EFFECTIVE WASTE MANAGEMENT IN AFRICA” Kigali Convention CenterRwanda 25th29th September2017
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Biogas Generation from Agricultural · PDF filewhich wet agricultural waste as well as sewage and ... –Generating a useful gas that can be used as a source of ... established for

Mar 10, 2018

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Page 1: Biogas Generation from Agricultural · PDF filewhich wet agricultural waste as well as sewage and ... –Generating a useful gas that can be used as a source of ... established for

Biogas Generation from Agricultural WastesAn Egyptian Experience in a Nile Delta Village (El Nenaiea)

Eng. HASSAN GOMAAEnvironment & Renewable Energy Consultant-Egypt

UNESCO-Africa Engineering Week with Africa Engineering Conference

THEME: “EFFECTIVE WASTE MANAGEMENT IN AFRICA”

Kigali Convention Center– Rwanda 25th– 29th September2017

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Eng. HASSAN GOMAAEnvironment & Renewable Energy Consultant-Egypt

Biogas Generation from Agricultural Wastes

An Egyptian Experience in a Nile Delta Village (El Nenaiea)

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INTRODUCTION:

• In this paper, we shall present an application ofusing a specific renewable energy technologyappropriate for use and replication in many ofour African villages and the countryside.

• The El Neneiea project serves a factory fordrying vegetables and fruits mainly Onions,Leek, Garlic, Carrot, Parsley, Beet, Tomato,Orange, Lemon, etc.

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• A biogas facility was established to:– provide gas fuel to save part of the huge amount

of diesel oil consumed for dehydration.

– producing compost to be used as a fertilizer .

– waste treatment and disposal.

• The first phase of the project saves 10% of thefuel consumption (around 1.5 tons/day and itis intended to cover 100% in the comingphases in the near future.

• Biomass/biogas has generally many advantages.

INTRODUCTION:

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Renewable Energy:

• The African countries are endowed with a variety of renewableenergy sources mainly hydro, solar, wind and biomass.

• The biomass represent a very important source.

• We as African engineers, our role are to develop utilization of ouravailable renewable energy resources to outmost possible forthe sustainable development of our countries economically,socially and environmentally.

• Energy is a key element for development particularly for theAfrican countries generally characterized by relatively low percapita specific energy consumption.

• Renewable energy offers a very encouraging energy source forthe well fair and sustainable development of the Africancountries as it will not only accelerate development but alsopreserve the environment.

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Biomass and Biogas :

• Biomass is one of most important renewable energytechnologies used, which depends mainly on utilizingall kinds of organic residues and wastes such asagricultural, trees and crop residues, animal residuessuch as animal dung and municipal wastes such ascity refuses and solid wastes as well as sewages.

• Biogas is a special type of biomass technologies inwhich wet agricultural waste as well as sewage andanimal dung are digested anaerobically to producebiogas that can be burned to produce energy fordifferent purposes leaving digested material as avaluable fertilizer.

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Biomass and Biogas :

• Biogas technology has several advantages mainly:

– Disposing of the agricultural waste in a safe way to preventthe otherwise potential of both land and water pollutionleading to health problems.

– Generating a useful gas that can be used as a source ofenergy to power agriculture industry and households.

– Prevent potential formation of more serious greenhousegasses such as methane.

– It will ultimately produce compost that can be used as landfertilizer.

– Increasing the efficiency of energy extraction.

– Raising the income and social standard in the rural areas.

– Offering new job opportunities.

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Biogas activities in Egypt:• Small-scale Biogas Activities:

Estimates from the Agricultural Research Center (ARC) and National ResearchCenter (NRC) show that there are 4000 small biogas (household) digestersinstalled in Egypt, less than 25% of them are in operation condition.Approximately 200-300 new plants are constructed every year. Meanwhile, thetotal potential for small biogas plants in Egypt is estimated to be more than 1million units.

• Large Scale Biogas Activities:

– On the large-scale level, due to heavy energy subsidies, biogas activities have notmoved away from the laboratory or pilot scale, unlike countries with no subsidies. Soonly few larger plants (up to 200 m3) have been constructed.

– A huge biogas plant of 220 000 m3 digester volume equipped by a 18 MW electricpower generation plant has been constructed by GOST and started operation, withinthe El-Gabal El-Asfer sewage treatment plant for Cairo Fig 1.

Fig. (1) El-Gabal El-

Asfer Biogas plant in

the Cairo sewage

treatment plant

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Biogas technology:• It is a technology for analysis/digestion of organic waste under anaerobic

conditions in the presence of a high percentage of moisture insidedigesters (fermenters) established for this purpose.

• Multiple dynamic activities of microbes and microorganisms genres actwithout human intervention or selection, except only creating the bestconditions; [Temperature ~ (35 or 55 0C), Ph (PH~7), Waste type (C/N =30), solid content ~ (10%), Stirring during fermentation, using prefixesand steroids (starter), presence of inhibitors, retention time] to increasedigestion/fermentation activity to the fullest extent possible.

• This results in a gas mixture generation composed of (55–70%) methaneand (42-29%) Carbon dioxide (3-1)% nitrogen & other gases (e.g. hydrogensulfide).

• This gas fuel mixture (biogas) is lighter than air and nontoxic, colorlessburning in blue clean flame, fit for use in internal combustion engines orstoves and furnaces after minor modifications.

• The material remaining after digestion can be used as compost or fertilizeror rich animal feed (according to the type of primary waste)

• The following figure (Fig. 2) shows the sequence/ stages of anaerobicorganic waste fermentation and gas fuel production

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Biogas technology:

Fig. (2) Three phase anaerobic digestion of organic material

and factors affecting biogas generation

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.

• Basic components: Digester, waste entry, digested waste exit systems, gas holder.• Secondary components: The first storage space, waste preliminary processing

area, heating& agitation systems, manure storage & processing systems.• Supplementary components: Waste transport and collection systems, manure

transport& spreading systems, gas distribution network, electric generator anddistribution network.

Fig. (3) Biogas

Integrated System

Components

Biogas integrated systems components:

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Biogas digester:• A digester must have a suitable space allowing anaerobic digestion conditions

and achieving the suitable conditions for the high activity of microorganisms.

• The digester volume must be enough for the available quantity of residues afterbeing mixed with water by a certain percentage.

• It must have a space to assemble and store the product gas to pull when neededfor use.

• It also shod have convenient way to introduce organic matter to the extent andin the form required, as well as a means to remove them after fermentation ordigestion to ensure continued efficient operation.

Fig. (4) Household

Small Biogas simple

design Digesters

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El Nenaiea Industry and Trading Co. Factory

• El Nenaiea Industry and Trading Company have a factory forvegetable and fruits dehydration with capacity of 100 – 125ton/day.

• The out coming wastes and residues are about 10-15% from themain capacity of the factory production lines.

• Dehydration process is a heavy energy consuming (20 – 30 ton ofDiesel oil/day).

• Due to the increase of energy prices in Egypt after decreasing thefuel subsides, this will make a heavy increase to the productprices of the company.

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El Nenaiea Industry and Trading Co. Factory

• One of the promising way to avoidthis increase of prices is to makebenefit of the company availablewastes as a source of renewableenergy through Biogas technologyand this will classify the companyproducts as green products andthis will open more marketingopportunities.

• The factory industrial organicwaste

Fig. (5) Waste disposal method before the biogas project & after no waste

accumulation

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Nenaiea factory biogas project :Primary stage:

• Manufacturing experimental models of biogas digesters (10 & 1000 liters size) for runningexperiments using the experimental models to evaluate the factory waste.

• The results were positive.

Fig. (6) Experimental models of biogas digesters (10 & 1000 liters size)

Biogas digester (10 liters size) Biogas digester (1000 liters size)

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• First stage (the first industrial model):

– First stage final Design Idea:

Fig. (7) First stage Design concept

Nenaiea factory biogas project :

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Steps of implementation:

Fig. (8) Building the body of the main basin fermenter in

the treatment area

Fig. (9) Installation of the main pump and its

connections for feeding & agitation, and heating & gas

systems

Nenaiea factory biogas project :

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Fig. (10) Design and manufacturing of the gas-collecting

tank and installing it above the fermenter

Fig. (12) Development of Biogas

generation During starting period

Fig. (11) Installing the burner unit which

works with Deuel diesel & biogas

Steps of implementation:Nenaiea factory biogas project :

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Fig. (13) Maim

components of the

digester

and

its Biogas generation rate

Digester start up and the its Biogas generation rate:

Nenaiea factory biogas project :

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o Why we go to 2nd stage:

– Through the deepening of local manufacturing, we proposed theproject "development and creation of economic units to treatorganic waste of food industries (liquid and wet) for productionof bio-fuel (Biogas) to run the boilers and for electricitygeneration as well as the production of organic fertilizer andirrigation water applying (anaerobic fermentation technology)”

Nenaiea factory biogas project : Second stage project

– The project is an application forthe principal investigator patent(municipal & industrial wastewatertreatment fragmented system thatcan be produced in massproduction works: (anaerobicallyor aerobically and anaerobically +aerobically) approved No.: 21867

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Nenaiea factory biogas project : Second stage project

o How we go to 2nd stage:

– The Innovative system of high efficiency and productivity can beapplied in many sites such as food factories, villages, resorts,camps and special settlements. Shown before.

– The proposed project adopts a short-term different stagesapproach implying that successful completion of a specific stagewould be an input to following stage and not start from scratch.Two experimental models of a high efficiency digester weremanufactured and used for testing different types of organic wastegenerated by the factory. After the promising results a digester asan industrial model of 450 m3 has been built with the factoryavailable capabilities and started and operated successfully usingthe available organic material in the factory. The operationmeasurements and results can be used for scaling up targetingcomplete usage of all wastes to meet all energy needs ofproduction.

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Nenaiea factory biogas project : Second stage project

o How we go to 2nd stage:

– The project has specific goals and multi- specialties are employedfor evaluation of the previous phases (the first industrial model)and add any complementary systems such as output gasprocessing and add the combustion systems' suitable forconsumption as diesel alternative fuel, as well as increasing thecapacity by an additional digester model/models to get benefit ofall amounts and types of organic wastes that have not been used.The new digesters will be designed and implemented as arepetitive modules which can be implemented quickly, efficientlyand of high quality in the sites with similar conditions.

– A project team of different parties will be formed to evaluate eachprevious phase, design, implementation and operation of thetargeted models comprising experts in civil engineering,mechanical electric, bio-chemistry with the beneficiary.

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Nenaiea factory biogas project : Second stage project

o How we go to 2nd stage:

– The beneficiary is one of the leading companies involved in dryingvegetables and fruits within a group of companies specialized inthe manufacturing of metallurgical equipment and particularlystainless steel and ready to finance with his kinships coveringproject manufacturing value.

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Fixed bed portion

Fluidized bed

portion Animal fresh

manure

Plant residues

Conical screw press

Biogas up grade

Acid phase

Liquid waste

Liquid fertilizer

Fluidizedfertilizer

FluidizedPlant residues

Fixed bed & Fluidized bed digester

Up graded Biogas

Fig. (14) The biogas plant main components and flow diagram

Nenaiea factory biogas project : Second stage project

o How we go to 2nd stage:

The biogas plant main components and flow diagram:

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The 1700 m3 digester design concept

(has Fixed bed & Fluidized bed sectors)

The digester 3D design (GLS tank)

Fig. (15) 2 phase 1700 m3 digester design concept and 3D design (GLS tank)The biogas plant have a Fixed bed & Fluidized bed digester

Nenaiea factory biogas project : Second stage project

o How we go to 2nd stage:

The biogas plant main components and flow diagram:

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Fig. (16) GLS tank construction on site

Nenaiea factory biogas project : Second stage project

o How we go to 2nd stage:

GLS tank construction on site :

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Conclusions:

o Lessons learnt indicate considerable rationale for El Nenaieaproject potential replication in Egypt as well as the Africancountries among which are the following :

Agricultural (crop & animal) residues can be considered the mostimportant traditional fuel not only in the Egyptian rural areas butalso in Africa.

As international pressures to reduce carbon dioxide emissionsgrow, humanity’s oldest fuel, biomass, is gaining a new lease oflife.

Biomass fuels fall into two main categories: energy crops andresidues where residues in Africa in considerable quantities.

Biomass fuels can either be burned directly, converted to refuse-derived fuel (RDF) or digested to yield gas.

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Conclusions:

o Lessons learnt indicate considerable rationale for El Nenaieaproject potential replication in Egypt as well as the Africancountries among which are the following :

The technologies, which may be employed to produce powerfrom biomass, range from the simple and inefficient to leadingedge technologies allowing wide spectrum use in Africa.

Improved technology may be the key to the economicdeployment of biomass.

More than half of the world population use wood andagriculture residues as a primary energy source for householdpurposes by burned in primitive mud stoves and ovens, orburned immediately in the fields after harvesting which leads togreat energy and economic losses as well as environmentalhazards.

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Conclusions:

o Lessons learnt indicate considerable rationale for El Nenaieaproject potential replication in Egypt as well as the Africancountries among which are the following :

Its total amount in Egypt is estimated to be 35 - 40 million tonsof dry-matter/ year, where 60 % of this quantity can be used forenergy purposes.

In the context of Biomass Technologies, it should be noted thatEgypt, as well as many African countries, is party to the UnitedNation Framework Convention on Climate Change (UNFCCC) thatdemands stabilization and reduction of CO2 emissions as well asother greenhouse gases, such as methane, according to Paristreaty of 2015 .

Biomass resources are CO2 neutral fuels, and increasing itsutilization for energy purposes will imply fewer emissions of CO2

and methane.

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