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This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag. 3. Biogas-Training Fertilizer Management of the Fertilizer Management of the Fertilizer Management of the Fertilizer Management of the Digestate Digestate Digestate Digestate Michael Köttner, International Biogas and Bioenergy Centre of Competence (IBBK) Nesta Nesta Nesta Nesta Boutique Hotel Ankara Boutique Hotel Ankara Boutique Hotel Ankara Boutique Hotel Ankara, , , , 12. 12. 12. 12.- - -13.09.2011 13.09.2011 13.09.2011 13.09.2011 1

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This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

3. Biogas-Training

Fertilizer Management of the Fertilizer Management of the Fertilizer Management of the Fertilizer Management of the DigestateDigestateDigestateDigestateMichael Köttner, International Biogas and Bioenergy Centre of Competence (IBBK)NestaNestaNestaNesta Boutique Hotel AnkaraBoutique Hotel AnkaraBoutique Hotel AnkaraBoutique Hotel Ankara, , , , 12.12.12.12.----13.09.201113.09.201113.09.201113.09.2011

1

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Fertilizer management of the digestateBiogas Training Workshop

1. Enviromental Aspects of Biogas Digestate2. Application of Digestate3. Digestate Processing4. Treatment Costs – Profitability5. Legal Aspects

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Fertilizer management of the digestateBiogas Training Workshop

1. Enviromental Aspects of Biogas Digestate

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Digestate production depending on installation size

Miehe et al. 2008

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Biology – properties of different manures

Liquid manure type pH -Value C/N Properties

Cattle liquid manure 6.8 – 7 10 – 17 • Good buffering capacity• Rich in methane bacteria

Pig liquid manure approx. 7 5 - 10• Good buffering capacity• High proportion of heavy

metals (Zn 700-2000; Cu 250-760 [mg/kg DM])

Poultry liquid manure 7 – 7.3 approx. 7 • Good buffering capacity• Strong sediment accumulation

Direct digestate application

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Modification of composition for different substrate s after passage through a biogas installation ( Peretzky 2008)

S ubstrate D igestate0

200

400

600

800

1000B ov ine s lurry

Organic

As hes

Water

Kg

/tfr

es

h m

as

s

90

28

93

25

S ubstrate D igestate0

200

400

600

800

1000C orn s ilag e

Organic

As hes

Water

Kg

/tfr

es

h m

as

s

S ubstrate D igestate0

200

400

600

800

1000Wheat (all c rop s ilag e)

Organic

As hes

Water

Kg

/tfr

es

h m

as

s

55

3

42

77

5

18

S ubstrate D igestate0

200

400

600

800

1000R ye (g rain)

Organic

As hes

Water

Kg

/tfr

es

h m

as

s

Fuchs and Drosg, 2010

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

S&H Umwelt GmbH & Co.

Environmental friendly (ecological) liquid manure management

Very big quantities of liquid manure lead to:

� Off Odor impacts during treatment and production� Spreading of pathogenic germs� Damage of the botanical composition and building of a typical

“Liquid Manure Flora” in the available grassland� Worsen the soil properties� Contamination of the ground and surface waters

Biogas technology can not substantially reduce liquid manure quantities. It

OFFERS HOWEVER, different solutions for this problem, thanks to its positive

energy balance from the production of biogas.

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Impact of selected substrate on digestate composition

Parameter Impact on digestate

Substrate influence

Energy Crops High DMHigh organic residue fraction [oDM/DM]

Bio wastes Lower DMLower organic residue fraction [oDM/DM]

High slurry fraction High azotic concentrationHigh NH4-N/TN

High slaughter house waste fraction

High azotic concentrationHigh NH4-N/TN

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Nutrients content and masse loss for for different Substrates

Substrate DM oDM N P Biogas production Masse loss

[%] [DM%] [kg/t] [kg/t] [m³/t freshmasse] [%]

Agricultural dung

Cowshed slurry 8-11 75-82 2,6-6,7 0,5-3,3 20-30 2-4

Pig slurry approx. 7 75-86 6-18 2-10 20-35 2-4

Cowshed manure approx. 25 68-76 1,1-3,4 1-1,5 40-50 5-6

Pig manure 20-25 75-80 2,6-5,2 2,3-2,8 55-65 7-8

Hen manure Approx. 32 63-80 5,4 - 70-90 9-11

Reneweable ressources

Corn silage 20-35 85-95 1,1-2 0,2-0,3 170-200 22-27

Rye 30-35 92-98 4,0 0,71 170-220 22-28

Sugar beet 23 90-95 2,6 0,4 170-180 22-23

Fodder sugar beet 12 75-85 1,9 0,4 75-100 10-13

Beet leaves 16 75-80 0,2-0,4 0,7-0,9 approx.70 9

Grass silage 25-50 70-95 3,5-6,9 0,4-0,8 170-200 22-26

Handreichung Biogasgewinnung und -nutzung (2006)

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Impact of selected process on digestate composition

Parameter Impact on digestate

Process influence

High fresh water fraction Higher quantity of produced digestate Lowering of salt concentration Generally less DM

High recyclated fraction Lower quantity of produced digestate Increase of saltconcentration Increase of DM

Hight inert materials fraction Increase of organic residues fraction decline [oDM/DM]

Short residence time High fatty acid valueHigh organic residues fraction [oDM/DM]Lower NH4-N/TN fraction

One phase or two phases process No significant impact on digestate composition

Fuchs and Drosg, 2010

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Positive changes of liquid manure properties

through fermentation

Odor reductionReduction of the odor causing substances (humid acids, Phenols, Phenol derivate)

Decomposition of organic substance

� Decomposition rates oDM: of up to 40% � The fermented liquid manure can pumped and sprayed better compared to

the raw liquid manure � The agitation is reduced before the application on land

Sanitization

The degree of the sanitization depends on retention time, temperature and applied procedure

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Hydraulic retention time (days)

Relative concentration (%

)

Odor reduction depending on retention time

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Positive changes of liquid manure properties

through fermentation

Destroying the weed seeds

The longer the seeds in the liquid manure are exposed to the process and the higher the temperature is, the more rapidly decreases the germination capacity

Avoidance of plant corrosion

Improvement of the fertilizer value

The fermented liquid manure has a better short term N-Fertilizer effect

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

1,00E+00

1,00E+01

1,00E+02

1,00E+03

1,00E+04

1,00E+05

1,00E+06

1,00E+07

1,00E+08

1,00E+09

GKZ EBA GCF FCF FKS

Keimart

Rohgülle

Biogasgülle

93,75%

99,90%

Anlage: Laukenmann Temp.: 38°C VWZ.: 80 Tage Typ: Betonfermenter Datum: Juni 1993

99,98%

99,70%

Messung durch Institut für

Tierhygiene, �

99,98%

Reduction of pathogenic germs

Plant: Laukenmann

Temp.: 38°C

HRT: 80 days

Type: Concrete digester

Date: June 1993

Raw l. manure

Biogas digestate

Measurements by the institute for animal hygiene, University of HohenheimGerms Type

Am

ount in

CBU

/g

CBU=Colony Building Units

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Mean values of some samples from cattle liquid manure and biogas digestate – Oberlungwitz biogas plant study case

� Cattle liquid manure

� Biogas digestate

Source: Saxony Regional Office for Agriculture FB LB, Jäkel

Kg/m

3

DM (%) Nitrogen Ammonium Phosphor Potassium Magnesium Calcium pH-value

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Heavy Metal load

Heavy Metals can not be reduced by the biogas process� Cadmium (Cd)� Chrome (Cr)� Quiksilver (Hh)� Plumb (Pb)� Copper (Cu)� Nickel (Ni)� Zinc (Zn)

Because drymatter content is lowered during biogas-process, the heavy metal concentration rises

After seperation most of the heavy metals content remains in the solid phase.

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Digestate can be spread on the fields

- no hygiene restrictions with animal slurry and plant material

Improved Fertilizer

- avoids nutrient losses

- reduces burning effect on plants

- improves flowing properties

- improves plant compatibility

- improves plant health

- reduces germination ability of weed seeds

Environmentally sound

- reduces the intensity of odor

- reduces air pollution through methane and ammonia

- reduces the wash out of nitrate

- sanitizes liquid manure

- recycles organic residues (co-fermentation)

- can avoid connection costs to a central sewer

5

Use of biogas digestate

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Fertilizer management of the digestateBiogas Training Workshop

2. Land Application of Digestate

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Liquid digestate processing and fertilization

Digestate storage

After the anaerobic treatment of liquid manure and during the storage nitrogen losses occur in form of ammonia

Digestate land application

During the application nitrogen losses can be presented in gaseous form (ammonia) and in mineral form (nitrate)

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Example from Denmark summarising the characteristics of four digestate and raw slurry application methods (adapted from Birkmose, 2009)

Trailing Hose Trailing-shoe Injection Splash Plate

Distribution of slurry Even Even Even Very uneven

Risk of amoniavolatilization

Medium Low Low or none High

Risk of cropcontamination

Low Low Very low High

Risk of wind drift Minimal after application

Minimal after application

No risk High

Risk of smell Medium Low Very low High

Spreading capacity High Low low High

Working width 12-28 metres 6-12 metres 6-12 metres 6-10 metres

Mechanical damage of crop

None None High None

Cost of application Medium Medium High Low

Amount of slurry visible

Some Some Veery little Most

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Land application techniques

Fertilizer distributor tractor: strong smell and ammonia emissions, wind-

sensitively

Drag hose tractor: precise fertilization, around 41% lower NH3 emissions

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

�No excessive agitation before the application�Deploy cooled substrate from the final storage�Spread using emission-reducing techniques (drag hose tractor, etc.), and �Processing the digestate

To prevent the nitrate leaching by liquid digestate fertilization other measures, besides the type of treatment must be taken into account:

�Sufficient storage capacity (at least 6 months)�Periods of application�Quantity of liquid digestate (and thus N-quantity) to be applied�Spreading technology

Measures during liquid digestate application

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Fertilizer management of the digestateBiogas Training Workshop

3. Digestate Processing

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Reasons for processing digested slurry

� Saves storage volume (liquid phase)

� Surplus of nutrients or lacking area for land spreading

Export of nutrients required

� Digestate contains 70-90 % of water

Removing water saves transport costs

� Reduced costs for land spreading

� Reduced environmental impacts

� Nutrients release in the liquid phase

� Reduction of volatile air pollutants

� Odor reduction

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Supply1000

Conditionning1000

Fresh water (wash water)

450

Fermentation2700

Digestate2450

Solid Digestate300

Liquid digestate900

Recyclate1250

Biogas250

1t substrate => approx. 850Kg digestate

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Basic principles of digestate processing

Liquid-solid separation

Membrane technology

Vacuum evaporation

� Physical

� Chemical � Flocculation

�Precipitation (MAP, Phosphate)

�Anaerobic digestion

�Composting (aerobe)

�Activated sludge process (aerobe)

�Nitrification, denitrification

� Biological

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Accumulation of further residues / side streams

solids: 15 %

microfiltration-concentrate: 20 %

(recirculation into the biogas plant)

reverse osmosis-concentrate: 15 %

(utilisation)

permeate: 50 %

digestate: 100 %

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Processing strategies

1. Partial separation 2. Complete separation

C, P2O5, Norg

N, P

N, K

N,P,K

Elimination of P2O5 Elimination of P2O5 + N

C, P2O5, Norg

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Applied Technologies

� Liquid-solid separation

• Screw press

• Decanter centrifuge

• Solar Drying

� Membrane technology

� Vacuum evaporation

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Liquid solid separation – partial processing

Separation of solid contents

always the 1st processing step!!!

� 20-80 % Ptot

� 10-20 % Ntot

Removal of:

� Production of compost

humus balance

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Nutrient distribution

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Distribution of significant parameters by solid pha se separation(Bauer et al. 2009)

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Spectrum of liquid phase composition after solid phase separation from digestate

Example of a wastetreatment equipment

Parameters Unit Liquid phase after solid phase separation

COD [mg/l] 15 000 – 80 000

BOD5 [mg/l] 1 000 – 15 000

TN (total nitrogen) [mg/l] 3 000 – 8 500

NH4-N [mg/l] 2 500 – 7 500

TP (total phosphorus) [mg/l] 100 – 1 000

PO4-P [mg/l] 50 - 800

DM [%] 1,5 -7

SS (? ) [%] 0,5 -6

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Exemplary nutrient distribution

� Partial processing

� Centrifuge – WLV

� Goal: P2O5 elimination

Type of nutrients to

eliminate leads to choice

of technology/ strategy:

P2O5: partial processing

N: complete processing

Source: WLV-Service GmbH, 2006

N: 78000 kg = 100%P2O5: 40234 kg = 100%K: 42843 kg = 100 %

N: 23288 kg = 30%P2O5: 27984 kg = 70%K: 42843 kg = 39 %

N: 55217 kg = 70%P2O5: 12250 kg = 30%K: 25940 kg = 61 %

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Liquid-solid separation - screw press

� 15-20 % DM

� approx. 5 % DM in liquid

phase

Removes:

�Simple device – often applied

�Required coarse material for efficient operation

�Wearing part: screen (depending on input matter)

Investment costs:

20.000 - 50.000 €

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Liquid-solid separation - Decanter centrifuge

� 30-40 % DS

� approx. 1-3 % DM in liquid

phase

Removes:

�Higher removal rate

�Suitable for subsequent

complete nutrient elimination

�Digestate’s properties =

criterium for device selection

Investment costs:

150.000 - 250.000 €Source: www.huber.de

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Decanter separation of the mixture digestate/ fats

Value and efficiency of nutrients and liquid manure

Source: Danish agrarian research

Liquid-solid separation - Decanter centrifuge

Raw liquid manure Fat waste Digestate (fermented liquid

manure) Solid fraction Liquid fraction

Weight portion (%) 97 3 100 7 93

DM content (%) 5,2 41,4 4,2 33 2,3

P (kg/t) 1,2 0,3 1,3 13,4 0,3

N-total (kg/t) 4,8 1,3 4,6 11,7 4,0

NH4-n (kg/t) 3,6 0,4 3,6 3,0 3,6

Org. N (kg/t) 1,2 0,9 2,3 2,6 2,3

NH4-n portion (%) 75 28 79 26 89

Source: Hengdal fermentation gas/Danish agrarian research

Fertilizer Efficiency nitrogen (%) Increase in value per t liquid manure €

Pig liquid manure 60 - 70 -

Digestate (fermented liquid manure) 65 – 85 0,30 – 0,60

Separated biogas digestate 80 - 90 0,60 - 1,20

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

� Water

� Partial N-losses

Removes:

�Simple technology – mainly applied for sewage sludge

�Combined utilisation of solar heat and waste heat

�Requires complex control system

Investment costs:

approx. 300.000 €

(digestate from 450 kWel. Plant)

Liquid-solid separation - Solar drying

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Heat coupled microgas turbine in combination with a solar supported

digestate drying process at the Farm at Karle, Fuessbach, Germany

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Complete nutrient separation

Elimination of P2O5 + N

� Complex processes, requires

sophisticated technology

� High energy demand

� Economically viable only at big biogas

plants > 700 kWel

C, P2O5, Norg

N, P

N, K

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Complete separation - Membrane technology

� Anaerobic digestion = best

preparation

� Requires good removal of coarse &

fibrous material (DM content ≈ 1

%)

� The better AD and solids separtion

were, the better performe the

membranes!

Quelle:www.haase-energietechnik.de 2007

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Example:

3-MW biogas plant

Vacuum evaporation

source

: ww

w.a

quasy

stem

s-tech

.de

Complete separation - (Vacuum-) Evaporation

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Complete separation What’s important?

� High energy demand for generating pressure or heat

utilisation of surplus heat ??

� Digested slurry might form crusts on the device

chose technology adapted to digested slurry

� Complete removal of particulate substances (> 0,2 mm) before

entering membrane technology or vacuum evaporation

Inaccurate solids removal increases rate of failure

Cleaning & Repair might take days and leads to

increased costs!

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Tractor truck with 2 hanger (load capacity every 14t)

Tractor truck with 2 hanger (load capacity every 14t) + 2,5 €/m³ output cost

Motor truck (25t)

Motor truck (25t) + 2,5 €/m3 output cost

Self-propelled unit for output + retrieval vehicule

Tractor truck with vacum baril

25

20

15

10

5

0

Specific costs [€/m

³]

0 20 40 60 80 100

Transport distance [km]

Output costs depending on transport distance

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Separated material – and now ???

� 1 substance 2-4 different material flows

� Concentrated nutrients might contain high salt loads

� Concentrated nutrients allow specific fertilizer mixing

� Utilization on own farm (partial nutrient removal)

� Marketing?

� Marketing channels?

� Quality assurance and control

Requires good planning &

strategic partners

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Fertilizer management of the digestateBiogas Training Workshop

4. Treatment Costs/Profitability

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Treatment costs of animal excrements

Technology Energy (kWh/t) Costs (€/m3) Application

Composting of solid manure5 -50 (for conversion

with ventilation system)12,4 – 37,2

No delimitation on farm size

Composting of poultry dung with pine cortex n.s. 8,1 (€/t) Test stage

Anaerobic ponds low n.s. Limited

Biological treatment of pig liquid manure 16 (5,6 % DM) 6,1 Large farms

Ventilation of liquid dung 10 - 38 0,7 - 4 Extensive experience

Mechanical separation 0,5 – 4 (kWh/m3) 1,4 – 4,2 Extensive experience

Incineration of chicken dung production 18 (€/t) > 130.000 fatlings

Evaporation and drying process of chicken dung

30 (kWh/m3 H2O) > 2,3 Test stage

Additives with pig liquid manure production 0,5 – 1 (€/animal) Routine

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

The total costs for a decanter separation are about 1,- € per t. accordingto data of a Danish biogas manufacturer. This price in Denmark isprofitable for many large cattle farmers.

A further separation in the evaporator is more expensive (approx. 3.40 €per t). This expenditure should be paid back by saved transport costs andby a better utilization of fertilizer as well as by the improved spreading.

Long distances transportation of manure for the fraction which cannot beused in the surroundings of the enterprise would be profitable

Economic value of digestate is indicated either as 10 € per LU per year orrelated to the nutrients also

55 €/ t N, 56 €/ t P,28 €/ t K.

Treatment costs

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Fertilizer value inprovement:

In areas where P2O

5 is not required, the one step treatment and

external transport make sense and could be profitable.

Partial separation - profitability

Nitrogen Phosphate Potassium

Cost of nutrients (€/kg) 0,60 0,45 0,35

NutrientsAmount C1

(kg/t)

Value C1

(€/t)

Amount C2

(kg/t)

Value C2

(€/t)

∆ Value C2 – C1

(€/t)

N 9,69 5,81 11,5 6,90 1,09

P2O5 4,97 2,24 13,82 6,22 3,98

K2O 5,29 1,85 8,35 2,92 1,07

Σ = 6,14

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Digestate output Separation Band-dryer Membrane

technicsConcentration Stripping

[€/m³ digestate]

Fixed costs 1,62 2,15 4,01 5,19 3,03 5,07

Energy and counsumables 0,29 0,30 3,74 2,77 7,03 3,42

Transport and output 4,42 4,77 4,53 3,17 2,82 2,21

Gross costs 6,33 7,23 12,28 11,13 12,88 10,70

Nutrients -4,40 -4,40 -4,26 -4,40 -4,40 -4,38

Cogeneration bonus - - -1,23 - -2,15 -0,88

Net costs 1,94 2,82 6,80 6,72 6,32 5,43

Comparison of specific costs for digestate treatmen t and conditionning process

(KTBL 2008)

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Fuchs and Drosg, 2010

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Conclusion

� Nutrients = problem (surplus) nutrient separation & export

might be the only solution

� But: calculate carefully (expensive technolgy) and be aware that you

might need to market nutrients

� Also: which nutrients do you need to get rid off – where are they?(nutrient distribution between liquid and solid phase)

� Complete nutrient removal is only viable at big biogas plants - not for

plants < 1 – 1,5 MWel

� Rising demand and increasing sizes of biogas plants might lead to

decreasing technology prices

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Fertilizer management of the digestateBiogas Training Workshop

5. Legal Aspects

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Description of digestate according to output material

and recommended analyse scale

Digestate description Biogas slurry Digestate Digestate

Outlet material element group Element group 1 Element group 2 Element group 3

Outlet materialInitial production

from agricultur and sylvicultur

Residues from conditionning and

treatement of agricultural products

Other biogenic residues (bio

wastes, animal coproducts)

Analyse scale Nutrients Nutrients, Heavy metals

Nutrients, heavy metals, organic

harmfull substance, hygiene

Fuchs and Drosg, 2010

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Feedstock DM % Total N NH4-N P K S Mg

Dairy cow slurry 6 3.0 2.0 0.5 2.9 0.4 0.4

Pig Slurry 4 4.0 2.5 0.9 2.1 0.4 0.2

Poultry :Layer Manure Broiler/Turkey litter

3060

16.030.0

3.212

5.710.9

7.515

1.53.3

1.32.5

Farmyard ManureCattlePig

2525

6.07.0

0.60.7

1.53.1

6.74.2

0.70.7

0.40.4

Example from the UK of approximate nutrient concentration of selected manure sources (kg/m³ or kg/t fresh weight) (MAAF, 2000)

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Maximum nutrient load

Required storage capacity

Compulsory season for spreading

Austria 170 kg N/ha/year 6 months 28 feb – 5 oct

Denmark 170 kg N/ha/year (cattle)

170 kg N/ha/year (pig)

9 months 1 feb - harvest

Italy 170-500 kg N/ha/year 90-180 days 1 feb -1 dec

Sweden 170 kg N/ha/year (calculated from

livestock units per ha)

6-10 months 1 feb – 1 dec

Northern Ireland

170 kg N/ha/year 4 months 1 feb – 14 oct

Germany 170 kg N/ha/year 6 months 1 feb -31 oct Arable land1 feb – 14 nov

Grassland

Example of national limits regulating nitrogen loading on farmland, required storage capacity for digestate, and its spreading season

(amended from Nordberg, 1992 and citation in Al Seadi, 2009)

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Biogas system Raw slurry

Pathogen 70°C (seconds) 53°C (hours) 35°C (days) 18-21°C (weeks) 6-16°C (weeks)

Salmonella T. 1 6 0.7 2.4 2.0 5.9

Salmonella D. 1 6 0.6 2.1

Coliform bacteria 1 20 0.6 3.1 2.1 9.3

Staphilococcus Aureus 1

8 0.5 0.9 0.9 7.1

Mycobacterium Para TB 1

8 0.7 6.0

Strep faecalis (FS) 1 3,92 mins 1.0 2.0

Group D Streptocococci 1

20 ? 7.1 5.7 21.4

M Bovis (TB) ² 90 nt nt 22.0 nt

Larvae of nemotodes ³

<0.6 <0.7 <2.4 <2.0 <5.9

Comparison of pathogen and nematode survival times in digestate and raw slurry (T90) (1Bendixen, 1994; ² Test carried out by ADAS; ³Bohm et al. 1999)

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Category Material

CATEGORY 1Not suitable for biogas / AD treatment

CATEGORY 2Can be processed in a biogas plant without preleminary treatment

Manure as well as digestive tract content (separated from digestive tract; if there is no risk of spreading serious-infectious diseases), milk and colostrum

CATEGORY 2Can be processed in a biogas plant after sterilisation with steam pressure

All materials classified as Category 2 (e.g. perished animals or animal slaughtered, but not intended for human consumption)

CATEGORY 3Can be processed in a biogas plant, in accordance with article 15 of the regulation 1774

All materials classified as Category 3 (e.g. meat-containing wastes from the foodstuff industry, slaughterhouse waste of animals fit for human consumption)

CATEGORY 3Can be processed in biogas plants which are approved in accordance with provisions and methods to be adopted, oraccording to national legislation

Catering waste, except originating from international means of transport (e.g. catering waste frominternational flights an trains etc)

Category of animal by-products not intended for human consumption, according to EC regulation no 1774/2002 and the conditions for their utilisation as feddstock

in biogas production (Kirchmayr et al. , 2003)

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Discharge requirements for agricultural applicationGroup 1 Group 2 Group 3 Group 4

GROUP 1 : Output from agricultural and sylvicultural basic production

Example

AVV number Description

020702 Waste from alcohol distillation : fruits, cereal or potato mashes, sludges

020107 Waste from forestry : rind, wood,wood rests

030101 Rind and cork wastes, wastes from wood conditionning and treatment

Not allowed in Zone II or rather within 50 days line

Nutrients in accordance with prescriptions for manures(total -N, Ammonium-N, Phosphat)

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Discharge requirements for agricultural applicationGroup 1 Group 2 Group 3 Group 4

GROUP 2 : Agricultural manures

Example

AVV number

Description

020106 Animal excrements : poultry dejections, porc and cattle slurry, manures

Output in water preserve and catchment bassins

Not allowed in Zone II or rather within 50 days line

Parameters to be analysed

Nutrients in accordance with prescriptions for manures(total -N, Ammonium-N, Phosphat)Precaution (ex : for mass animal husbandry) :Spore forming bacteria, parasite, antibiotic, other animal drugs

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Discharge requirements for agricultural applicationGroup 1 Group 2 Group 3 Group 4

GROUP 3 : Residues from conditioning and treatment of agricultural produces

Example

AVV number Description040221 Wastes from untreated textile fibre : cellulosic fibres,

plant fibres, wool

200108 Organic biodegradable cooking and catering wastes

020799 Production of alcoholic and not alcoholic drinks : malt grain, hop grain, slush from brewery, wine lees, marc, yeast residue

030105 Sawdust, shavings, wood conditionning and treatment, manufacture of furnitures

Not allowed in water preserves and catchment bassins as well sensible fields; exception for protect zone III with appropriate

administration and aditional analyses and acceptance of upper limits

Nutrients in accordance with prescriptions for manures(total -N, Ammonium-N, Phosphat)For exceptions : heavy metals, salmonelaPAH, AOX, surfractants, spore forming bacteria, parasite, antibiotic, other animal drugs

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Discharge requirements for agricultural applicationGroup 1 Group 2 Group 3 Group 4

GROUP 4 : other organic wastes (biowastes, animal coproducts)

Example

AVV number

Description020203 Fat wastes (fish or meat conditionning)

020204 Fat strainer, flotation tailings (fish and meat conditionning)

- Lop from roadsides and industrial areas

- Excrements from meat eating animals and contamined areas for this reason (Excrements from zoo animals, animal shelters, contaminated grass cutting from dog exercices areas)

200302 Market wastes (only biodegradable parts)

Not allowed in water preserves and catchment bassins as well sensible fields; no exception

Nutrients in accordance with prescriptions for manures(total -N, Ammonium-N, Phosphat)Legal prescription :If applicable : heavy metals, salmonelaPAH, AOX, surfractants, spore forming bacteria, parasite, antibiotic, other animal drugs

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Analyses frequency

Continuous and on 1 year evenly distributed. At least : � six-monthly for installations with a flow capacity <3000 t/a � three-monthly for installations wirh a flow capacity >3000 t/a

Aditional analyses for significant changing in nutrientcontent, in particular for changing type and composition ofco-substrates or changing in fermentation process

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Need for seals of quality

RisksDigestate spread can lead to an accumulation of contaminent� on the ground � on seepage water zone� In ground water

Need for a seal of quality system� Voluntary seals of quality are not sufficient (drugs, cleaning agents, virus/bacteria …)� Quality assurance by biogas operator is essential with limit values, particularly for digestate spread into water preserve and catchment bassins � Alternative in case of non-respect for sanitary norm : energetic (thermic) recycling

This project is part of the International Climate Initiative. The German Federal Ministry for the Environment, Nature Conservation and Nuclear Safety supports this initiative on the basis of a decision adopted by the German Bundestag.

Thank you for your attention!

67

Turkish-German Biogas ProjectDeutsche Gesellschaft fürInternationale Zusammenarbeit (GIZ) GmbHAnd Sokak No: 8/1106680 Cankaya/Ankara, TURKEY

T +90 312 466 7056T +49 6196 79830 007E [email protected] www.giz.deI www.biyogaz.web.tr

Author:Michael Köttner, International Biogas and Bioenergy Centre of Competence (IBBK)