The Bionic waste treatment systems Microfuel and Bio-Elite Fertilizer come together in an integrated waste management concept. The presentation shows how an unusual high level of energy and nutrient recovery from waste can be achieved. www.bionic-world.net English Version, August 2012
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Fuel & Fertilizer from combined processing of waste streams
(municipal solid waste, used tyres, biomass and animal manure)
Public prosperity requires economic growth, which in turn requires sufficient availability of energy.
Raising production requires more automation and mechanization
More production requires more goods to be moved from production sites to markets
More economic growth requires more people to be moved from home to work
More personal prosperity raises private expectations on quality of life
Increasing energy demands from machines
Increasing energy demands of logistic operations
Increasing energy demands of public transportation
Increasing energy demands of private transportation Increasing energy for private housekeeping
Without enough affordable energy national economic growth is highly limited. The right sources of energy must be found for each national economy.
Solar energy Wind energy Water energy Energy from Waste streams
Energy based on fossil fuels
To expensive at this time for emerging countries, cannot be used for all national energy demands
Favorable, but requires back up source of energy depending on weather. Not sufficient for all national energy demands
Favorable, but requires appropriate rivers, cannot be used for all national energy demands
A clear option for the future
High and unstable prices at world markets, continually increasing prices in the future
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ENERGY FROM WASTE
Valuable fuel and chemical products can be recovered through the smart use of household and commercial waste materials.
More than 70% of municipal solid waste can be processed with MWDP. The organic fraction can be converted into a stabilized bio fertilizer*. Mixed with the bio-char fraction a highly valuable soil amendment can be produced.
Instead of destroying waste materials in enormously expensive and complex incineration plants, which still produce large amounts of greenhouse gases, the Bionic portfolio of advanced microfuel technologies allows for a far more cost effective, sustainable and clean solution.
* Bionic has licensed the patented German Bio-Elite process which produces a highly effective Bio-NPK from organic waste combined with animal manure and a proprietary mix of micro organisms
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MICROWAVE DEPOLYMERISATION
In 2003 Bionic initiated the development of its unique proprietary Microfuel Technology. Two depolymerization methods working in principle were combined into a new, revolutionary conversion process capable of transforming any carbonaceous feedstock material into liquid and solid fuel. Bionic merged for the first time the independent direct conversion methods Thermal Catalytic Depolymerization (TCDP) and Microwave Pyrolysis (MP) into a single hybrid process called Microwave Depolymerization or MWDP. While TCDP was known for decades many hurdles for commercial implementation where never overcome. Adding microwaves to the process did not only eliminate all prior design issues of heat application but added also a number of beneficial effects unique to the use of microwaves in chemical reactions. In 2007, after years of R&D in the lab, the first continuous reactor design was ready. Microfuel process and reactor design proved their outstanding capabilities in a pilot plant running 2008/2009. The current design of the standardized commercial MF480 base model followed. In 2013 a technology demonstrator based on the downscaled MF60 goes online marking the final step to commercialization. Highly effective zeolite catalysts and other additives are used in the process assisted by the treatment with advanced, proprietary microwaves. Bionic’s microfuel plants are the most economic and efficient way commercially available to produce clean liquid fuels from biomass and waste materials. With minimal upgrading the liquid product fraction can be used in even the latest diesel engines summer and winter.
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PLASTIC WASTE TO OIL
Common plastics today derive from fossil oil, not surprisingly the plastics fraction of municipal waste can be converted back to oil
MWDP extracts and concentrates the energy locked up in the complex carbonaceous molecules contained in the chosen feedstock. In other words:
Energy contained in biomass and waste materials is transformed into liquid and solid fuels which are
indefinitely storable and have a controlled consistency.
The resulting light oils can be used at a later stage for transportation or heating.
Toxic substances in the plastic waste are either transformed in the process or removed from the liquid fraction. Inert minerals contained in the feedstock remain unchanged and can be removed from the solid char fraction if desired. As a byproduct a combustible gas fraction is produced which fuels part of the internal power generation.
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HOW IT WORKS
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PROCESSING OF WASTE STREAMS
Processing of various waste streams:
Plastics, Textiles, Scrap Tyres (RDF) conversion to -> oil und char
Organic Waste, food waste, biomass processing to -> Bio-Elite fertilizer
Anorganic Waste, ceramics, metals
Separation and Recycling Water
Usage as process water, cooling etc.
~ 32%
~28%
~14%
~26%
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MSW used tyres plastic waste organic waste
manual presorting
shredding and sorting
metals PET glass + stones
organic waste & manure
High caloric Fractions (RDF)
Bio-Elite composting Bio fertilizer
light oils for power generation
char for power generation
heating oil, electricity and heat
decentralized generators & power plants coal power plants
grid
BIONIC WASTE SYSTEM
ADVANTAGES OF BIONIC‘S NETWORK
Bionic waste systemdecentralized tyre processing facilities
Input:municipal waste streams
Output:Oil, Char, Gas
decentralized CHP plants existing charcoal power plants
power generation
Bionic‘s innovative proprietarycatalytic microwave depolymerisation process
Germany‘s leading technologies forwaste processing and engineering & logistics
decentralized power generation
150 years of production know-howfrom Czech Republic, delivery of core reactors
deep involvement oflocal production industry
unique system for fertilizer productionwith experience of more than 20 years
proof of concept by proof of viability by small available units
cooperation of local partners inthe bionic network
exclusive granting of licenses from Bionicfor production and exporting the system to support local Industry
electric energy, fuel and fertilizers to the people out of municipal waste streams
(based on bionic‘s innovative microwave depolymerisation process)
financing provided byinternational partners
following the international attempts of generatingenergy from waste streams with environmentalfriendly solutions
extensive know-how transfer from Germany
fertilizer production
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ENVIRONMENTALLY FRIENDLY
Fully contained processing system Near emmission free technology (except exhaust gases from power generation) Low temperature, oxygen free processing (< 400°C) All outputs are usable – no residual waste High conversion rate for storable fuels Small footprint Local industry involvment Job creation No water or air pollution Decentralized implementation Minimal transport requirements Highly innovative technology developed in Germany
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MICROFUEL BTL REACTOR
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The complete high tech assembly is fully contained in a reactor housing. A single unit has a capacity of up to 80 tons of feedstock per day.
Zeolite Catalyst
oil
char
Waste containing hydrocarbons
modulated pulsed microwaves
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MICROFUEL PROCESS
The microfuel system was developed by Bionic with R&D starting as early as 2001. Microfuel is the most sophisticated TCDP process technology available worldwide ready for commercial deployment.
The waste material is shredded to a fragment size of 40 mm2 or less. Then the shredded chips are mixed with additives and pelletized before conversion in the microfuel reactor into oil and char. Valuable by-products are often found – for example, glass & metals – which can be sold to the respective markets.
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FLOWDIAGRAM
Gas 264 kg Oil 1584 kg Char 1386 kg Water 66 kg Heat
preparation conversion output
3.300 kg/h Dried feedstock separated from municipal solid waste
~ 8,0%
~48,0%
~42,0%
~2,0%
microfuel MF 480w
1.500 kW CHP
material flow per hour for a single reactor
600 kW (el) 250 kW (therm)
~ 8 % of liquid fuel for internal
energy
~ 500 kW @ 90°C (from energy recovery)
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MASS BALANCE
QUALITY OF THE OIL
Oil from the microfuel process meets relevant standards for transportation and heating fuels. It can be used for energy production in stationary diesel engines. With common blending methods and hydro-treatment quality can be upgraded to low sulfur transportation fuels. Exact oil quality depends on the chosen feedstock. The table shows oil analytic results from a biomass feedstock. Oil from plastic waste has similar properties.
Bio-Oil Analyticscomparing to ASTM specifications for low-sulphur fuel
Flash point ASTM D 93 / DIN 2719 °C 56,5 52,5 min 38Kin. Viscosity (40 °C) ASTM D 445 / DIN 3104 mm2/s 1,126 1,319 1.1 - 2.4Lubricity HFRR 60°C ASTM D 6079 µm 389 357 max 520Ash content ASTM D 482 / DIN 6245 % (m/m) < 0,005 < 0,005 max 0.01Sulfur content ASTM ASTM D 2622 % mass 0,044 0,007 max 0,05Density (15 °C) ASTM D 1298 kg/m3 832,9 852,6 820 - 845Distillation temp ASTM D 86 correlation °C 204,4 368,8 max 288Cetane index ASTM D 976 - 40,1 40,3 min 40Nitrogen content ASTM D 4629 mg/kg 2500 177 no specificationCooper strip corrosion ASTM D 130 Corr Degree 1A 1A max No 3PAH content (Aromates) ASTM D 1319 / DIN 12916 % (m/m) na 0,9 max 35Cloud point ASTM D 2500 / DIN 23015 °C -16 -16 < 35°CCFPP ASTM D 6371 / DIN 116 °C -49 -55 < - 20 °C for winter gasoilCalorific value, lower ASTM D 240 DIN 51900 J/g 39797 37158 -Calorific value, upper ASTM D 130 / DIN 51900 J/g 42053 39684 -
The microfuel process concentrates the energy content of the feedstock. Char, the main byproduct, can be used replacing anthrazite coal as a solid fuel. Exclusive use of biomass as feedstock will result in a perfect biochar for soil enhancement. Char from waste streams is a high energy solid fuel.
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FEEDSTOCK PREPARATION
Bionic is using high quality preprocessing equipment from German market leaders. Degree of mechanization depends on local conditions and client preferences. Available equipment can be integrated.
MANUFACTURING
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Bionic‘s microfuel system is manufactured adhering to the highest technical standards: - Manufacturing of core units by SMERAL a.s., BRNO, Czech Republic - Feedstock preparation equipment, vacuum system, generators and
control units come from leading German suppliers. - All suppliers are approved by Bionic‘s quality control.
Bionic‘s microfuel system complies with all major technical standards: DIN EN ISO 9001 ASME Div 01, Div 02 (AIA TÜV, Germany) CE conformation declaration ATEX 94/9/EU explosive protection conformity Machinery directive EU 2006/42/EU Dual radiation protection by special Faraday cages Double insulation of all oil containing parts Advanced fire protection system Hazard protected electronic control equipment Redundant process emergency control system Automatic emergency shut down process Unit made from high quality stainless steel Production and installation certified by German TÜV or SGS 19
TECHNICAL STANDARDS
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FERTILIZER FROM ORGANIC WASTE
Bionic licensed the patented Bio Elite – waste-to-fertilizer technology for its process train. Bio Elite, with more than 20 years experience, is a composting method which allows controlled treatment of the organic fraction of MSW. The mix of municipal waste and specially selected bacteria and funghi under a controlled climate converts the organic content of waste into a high value normalized Bio-NPK fertilizer. Contaminations of the organic waste, such as germs, antibiotics or virusus will be destroyed during the process. All types of animal manure can be added to improve quality for direct use on field as a soil-enhancer. Bionic Char can be added for innovative soil improvement products. Several studies from public institutes have validated the process and demonstarted that Bio Elite fertilizer can substitute synthetic fertilisers. A license model allows for the production of sufficient amounts of fertilizer at low cost. Sale of biologically produced fertilizer from municipal waste generates additional income instead of loading up landfills. The Bio-Elite composting system is also available for processing of animal manure as a standalone system with many advantages.
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FERTILIZER PRODUCTION
CONTINUOUS SOIL IMPROVEMENT
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Eroded soil Soil stabilization with agro-forestry
Recovery and continuous improvement of eroded soils to valuable farmland can counter the current global desertification trend
With continuous soil improvement farming becomes sustainable again: • 2-3 time faster growth of bio mass • up to 3 crops under irrigation
Continuous addition of Bio-Elite
No synthetic fertilizers required
RECLAMATION OF DEPLETED SOILS
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Raising the amount of biomass grown CO2 absorption volume will be constantly increased from the very beginning of farming on formerly depleted soils Significant positive overall CO² footprint
Eroded savanna soil depleted through unsustainable farming or mining activities
Soil stabilization through agriforestry backbones
Growing high value foodcrops between hedges
Growing maize and other grains between hedges
Low impact clearing
No-till farming
Organic fertilizer, bio-char
DECENTRALIZED POWER GENERATION
The Finnish company Wärtsilä is a world leader for large stationary Diesel and Gas Engines and CHP Power Plants. Ready concepts have been developed for Bionic fuelled decentralized power generation providing electricity and heat to municipalities.
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REQUEST FOR INFORMATION
To prepare an orientation offer the following information is needed:
Client contact details Detailed information about client‘s intentions and background exact geographical location of the project annual expected waste streams including monthly deviations feedstock analysis reports (plastics, synthetics, organics, mineralic) local climate conditions description and plan of location description of available waste processing technology description of available waste collection logistics Pictures/video of available waste processing technology and landfill local wholesale price for heating oil (per liter, low-sulphur,> 40 MJ/kg cal. value) local supplier price for electric power(per kWh, electric load 500 kWh) local wholesale price for NPK fertilizer recycling facilities for PET, PVC, glass and metall near location (<80km) distance to next cement factory or solid fuel power plant distance to next oil refinery type of operator: municipal, public or private company
All information in German or English please.
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INVESTMENT BUDGETS Project planning: Project pre-feasibility, qualification and calculatio 25.000 € Original feestock, in/output qualification (excl. Shippi 75.000 € Detailed feasibility study approx. 350.000 € Typical turn-key facility single reactor: (semi-automatic sorting equipment, reactor, 1,2 MW genset, composting facility, oil-condensation) MSW capacity: 220 MT/day input, > 25 to oil output approx. 17.500.000 € > 100 to fertilizer output > 45 to char output Typical turn-key facility 4-reactor cluster: (sorting equipment, 4 reactors, 3 x 1,5 MW generators composting facility, oil-condensation) MSW capacity: 880 MT/day Input, > 100 to oil output approx. 57.000.000 € > 400 to fertilizer output > 140 to char output Budgets listed above are for standard MSW and for orientation only. Not included are expenses for land, infrastructure and product upgrading. Capacity is highly dependent on actual feedstock composition.
FINANCIAL FEASIBILITY - EXAMPLE
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Business Plan (condensed) Bionic mf480KR Municipal Waste processing rev 35 20.08.2012
Input Capacity Municipal Waste 73.100,00 [ tons / year ] Annual calculation assuming 7310 Hours operating time per year
Investment volume: 17.401.871 €
OutputsOutput of Oil 7.953 [ tons / year ] Process lost ( water ) 15.205 [ tons / year ]Output of char 13.567 [ tons / year ]Output of usable fertilizer 33.158 [ tons / year ]Valuable Byproducts (metals & glass) 3.216 [ tons / year ]
IncomeIncome from municipality for waste (Germany ~ 150€) 25,00 € [ €/t ] 1.827.500 € Sale of Oil (Heating Oil quality, 1% Sulphur) 350,00 € [ €/t ] 2.783.648 € Sale of Char ( 22MJ/KG ) 40,00 € [ €/t ] 542.694 € Sale of fertilizer (similar NPK) 60,00 € [ €/t ] 1.989.490 € Sale of heat, metal & glass waste 562.870 €
7.706.202 €
Costsoperation costs, including addons, employment costs, office and maintenance 3.357.289 € financing costs, including repayment, interest & debriviation, Base 10 years 1.183.327 €
4.540.616 €
EBIT 3.165.586 €
Based on standard municipal waste: ( 26% water / 28% organics / 6% sand / 5% glass / 3% metals / 32% plastics )Calculation hardly dependet on contents of feedstock.
viability in detail
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business calculation (sample) municipal waste processing rev 35 20.08.2012
year 0 1 2 3 4 5 6 7 8 9 10 Totalfigures setup startup year full productionnumber of reactors 1 ( production period) 50% 100%runtime [hrs] (85% availability) 7310 hinput capacity feedstock total (German standard contents) 10,00 t / hInput capacity Total per year t / h 36.550,00 73.100,00 73.100,00 73.100,00 73.100,00 73.100,00 73.100,00 73.100,00 73.100,00 73.100,00 694.450 input capacity feedstock / hr for depolymerisation 3,2 t / h - 1,60 3,20 3,20 3,20 3,20 3,20 3,20 3,20 3,20 3,20 input capacity dry per year for depolymerisation t / a - 11.696 23.392 23.392 23.392 23.392 23.392 23.392 23.392 23.392 23.392 222.224 Output capacity fertilizer per year t / a 16.579 33.158 33.158 33.158 33.158 33.158 33.158 33.158 33.158 33.158 output oil per hr 34% kg / h 0,54 1,09 1,09 1,09 1,09 1,09 1,09 1,09 1,09 1,09 output capacity oil per year t / a 3.977 7.953 7.953 7.953 7.953 7.953 7.953 7.953 7.953 7.953 75.556 output capacity char per year 58% t / a 6.784 13.567 13.567 13.567 13.567 13.567 13.567 13.567 13.567 13.567 128.890
Based on standard municipal waste: ( 26% water / 28% organics / 6% sand / 5% glass / 3% metals / 32% plastics ) final repayment of loan after 10 years 0 € Calculation hardly dependet on contents of feedstock. ROI after 10 years 43.426.786 €
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GLOBAL PARTNER NETWORK
Bionic is developing a global partner network to accelerate its presence worldwide: - Sales partner with a strong position in a relevant industry - Project development and installation - After sales customer care, maintenance and supply of expendables - Local sourcing and procurement - Joint Venture for manufacturing If/when certain conditions are met exclusivity will be granted for a defined area.
Bionic Group of Companies represented by:
Bionic Laboratories BLG GmbH, Germany
For more information visit us at www.bionic-world.net