PRODUCTION OF 3rd GENERATION FUEL AND FERTILIZER ON LOCAL SOURCES OF AGRICULTURAL WASTES AND CROP RESIDUES A principle flexfuel example technology a/s BIO Technical Director Torben A. Bonde Mobile: +45 21 49 59 40 [email protected]
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PRODUCTION OF 3rd GENERATION FUEL ANDFERTILIZER ON LOCAL SOURCES OF
AGRICULTURAL WASTES AND CROP RESIDUESA principle �exfuel example
t e c h n o l o g y a / sBIO
Technical Director Torben A. Bonde
Mobile: +45 21 49 59 [email protected]
A principle �exfuel example 2
Pig / cattle slurry Deep litter, straw etc.
Pig / cattle slurryPig / cattle slurryPig / cattle slurryLigno-cellulose
Hydrolysis
Fermentation
Ethanol recovery
Fermentation
Separation
FLEXFUEL - PROCESS DIAGRAM
Bioethanol
Biomethane
Fertilizers
Pure water
A principle �exfuel example 3
FLEXFUEL - BIOMASS INPUT
Biomass:• Slurry (pig / cattle) 100.000 tons 4.000 tons TS• Deep litter 10 - 20.000 tons 4.500 tons TS• Straw 10.000 tons 8.500 tons TS
Production:• 5 mio. l bioethanol• 2,5 mio. m3 biogas• 10.000 m3 NKS-fertilizer (700 tons N, 400 tons K, 200 tons S)• 4.000 tons P-fertilizer (200 tons P)
• 90.000 m3 water
A principle �exfuel example 4
Pig / cattle slurryPig / cattle slurryPig / cattle slurryBiomethane reactor
Fiber separation
Conditioning
UF - �ltration
RO - �ltration
FLEXFUEL - SEPARATION
P - fertilizer
NKS - fertilizerAcid
Water
A principle �exfuel example 5
A SILICON CARBIDE MEMBRANE BASED FERMENTATION SYSTEMWITH ENZYME, CELL AND PERMEATE RE-CIRCULATION AND MEMBRANE ETHANOL RECOVERY
MembraneEthanol recovery
Particles and enzymere-circulation
1
2
3
Enzyme reactor Ethanol
bioreactorsUF �lter
4
Broth re-cycling
Ethanol koncentrate
Bleed, for biomethaneand separation
A principle �exfuel example 6
FLEXFUEL – PLANT OUTLAY
UF and ROPower etc.
O�ces etc.
Fiberreception
andstore
Meso�lebiomethane
fermenter
Receptiontank
N - fertilizer
P - fertilizer
Gas cleaningChemicals
Separation�ber and
slurry
FermentationLiquidation
EtOH recovery
HydrolyserBoiler
Gas engine
SEPARATION SECTION
FERMENTATIONSECTION
RAW MATERIALSECTION
A principle �exfuel example 7
FLEXFUEL – PLANT ILLUSTRATION
A principle �exfuel example 8
FLEXFUEL - ECONOMY
Production values:• 5 mill l bioethanol (0,5 € per l) 2.500.000 €• 2,5 mill m3 biomethane (0,25 € per m3) 625.000 €• Fertilizer 500.000 €• Reduced storage, transport, application (net 3 € per tons) 300.000 €• Side benefits (increased livestock production etc.) 0 €• Total sales 3.925.000 €
Running costs:• Biomass (no fee, no transport (variable)) 0 €• Power 20 kWh / m3 250.000 €• Enzymes, chemicals, yeast 200.000 €• Maintenance (2,5 % of capital investment) 250.000 €• Staff (4 full time employees) 200.000 €
Capital, depreciation (8% of 10 mill investment) 800.000 €• Total costs 1.700.000 €
Annual surplus 2.225.000 €
A principle �exfuel example 9
FLEXFUEL – SUMMARY
The positive economical outcome is determined by:
• The technology break through in terms of liquid separation and ethanol recovery.
• Small to medium scale plants - readily access to inexpensive biofuel substrates.
• Production of flexfuel (bioethanol versus biomethane depending on the specific market).
• Effective production of bioethanol (continuous fermentative systems).
• Minimal use of process energy (membrane processes for ethanol recovery and liquid separation).
• Production of fertilizer on remaining stillage/digestate (no waste generation).
• Waste to value (the manure problem is solved).
• Additional side effects (reduced GHG emissions, increased livestock and agricultural production, new working places in rural districts etc.)
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