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University of Verona, Department of Biotechnology Nutrients recovery from anaerobic digestate of agro waste: techno economic assessment of full scale applications N. Frison, F. Fatone, D. Bolzonella Department of Biotechnology, University

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University of Verona, Department of Biotechnology

1 Cyprus 2016

Nutrients recovery from anaerobic digestate of agro‐waste: techno‐economic assessment of full scale applications

N. Frison, F. Fatone, D. Bolzonella

Department of Biotechnology, University of Verona

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University of Verona, Department of Biotechnology

2 Cyprus 2016

Nutrients are essential for crops growth, that’s why we use mineral fertilisers

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University of Verona, Department of Biotechnology

Cyprus 2016 3

We need nutrients ! 9 billion people Foto Campi …….

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University of Verona, Department of Biotechnology

Cyprus 2016 4

However, nutrients are sometimes scarce ….

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University of Verona, Department of Biotechnology

Cyprus 2016 5

And reserves are in the hands of few Countries ….

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University of Verona, Department of Biotechnology

Cyprus 2016 6

> 8600 AD digestate can be the new mine for EU ! More than 14,000 AD plants wthin EU, 1100 MWel installed

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University of Verona, Department of Biotechnology

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Anaerobic digestate of agro‐waste can be the new mine

N P K

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University of Verona, Department of Biotechnology

Cyprus 2016 8

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University of Verona, Department of Biotechnology

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Technologies for nutrients recovery are plenty !

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University of Verona, Department of Biotechnology

Cyprus 2016 10 Plant Feedstock Plant Size, kW Digestate treatment Products A1 Pigs effluents, chicken manure, energy crops 999 Dryer Ammonium sulfate and dried organic digestate A2 Cow manure, energy crops, slaughter house residues (blood), food waste 999 Dryer Ammonium sulfate and dried organic digestate B1 Pigs effluents, energy crops 999 Membrane separation Reverse osmosis centrate, ammonium sulfate, water B2 Cow manure, energy crops 600 Membrane separation Reverse osmosis centrate, ammonium sulfate, water C1 Cow manure, pigs effluents, energy crops 350 Stripping Ammonium sulfate

AD farm plants monitored in this study

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University of Verona, Department of Biotechnology

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Drying process

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University of Verona, Department of Biotechnology

Cyprus 2016 12

Drying process

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University of Verona, Department of Biotechnology

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Ammonium sulfate Dryed sludge

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University of Verona, Department of Biotechnology

14 Cyprus 2016

Mass balance for plant A2 Ammonium Sulfate Flow, m3/d 1,7 Nitrogen, kgN/d 61 Scrubber Digestate Dried solids Flow, m3/d 13 Flow, m3/d 1,8 Dry solids, kg/d 1700 Belt dryer Dry solids, kg/d 1673 Nitrogen, kgN/d 121 Nitrogen, kgN/d 49 Phosphorus, kgP/d 10,5 Phosphorus, kgP/d 10 Mass balance for plant A1 Ammonium Sulfate Flow, m3/d 3,8 Nitrogen, kgN/d 82 Scrubber Digestate Dried solids Flow, m3/d 32 Belt dryer Flow, m3/d 4 Dry solids, kg/d 3792 Dry solids, kg/d 3758 Nitrogen, kgN/d 189 Nitrogen, kgN/d 89 Phosphorus, kgP/d 12 Phosphorus, kgP/d 11

Heat availability is the limiting step: only 20 m3/d

f water (maximum) can be removed, so nitrogen

recovery is limited to < 40% of influent N, but around 90% of P in the dryed solids

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University of Verona, Department of Biotechnology

Cyprus 2016 15

Stripper Adsorber Stripping and ammonium sulphate recovery

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University of Verona, Department of Biotechnology

16 Cyprus 2016

Stripping and ammonium sulphate recovery NH3,L NH3,air Liquid w/o NH3 Liquid phase rich in NH3 H2SO4 (NH4)2SO4 (pH  5) NH3,air Qair Warm Air Off gas QL Qair Stripper Ad- sorber Base

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University of Verona, Department of Biotechnology

17 Cyprus 2016

SP Liquid S Liquid Liquid Q, kg/d 116000 89% Q, kg/d 102000 78% Q, kg/d 102000 78% DM, kg/d 4378 64% DM, kg/d 3836 56% DM, kg/d 4272 63% TN, kg/d 406 87% TN, kg/d 355 76% TN, kg/d 277 60% Digestate TP, kg/d 40 62% TP, kg/d 22 34% TP, kg/d 20 31% Q, kg/d 130000 Screw Settler Stripping DM, kg/d 6792 Press column TN, kg/d 465 TP, kg/d 65 SP Solid S Solid Ammonium sulfate Q, kg/d 14000 11% Q, kg/d 14000 11% DM, kg/d 2568 38% DM, kg/d 543 8% Q, kg/d 3000 TN, kg/d 58 12% TN, kg/d 50 11% TN, kg/d 78 17% TP, kg/d 21 32% TP, kg/d 15 23%

Several key points: fraction of N as ammonium (a), heat, solids removal before stripping

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University of Verona, Department of Biotechnology

18 Cyprus 2016

Membrane processes Digestate Solid to fields Cationic flocculant Liquid

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University of Verona, Department of Biotechnology

19 Cyprus 2016

Solids to fields Centrate Permeate (water) Liquid UF RO

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University of Verona, Department of Biotechnology

SP Liquid C Liquid UF Liquid RO Liquid Q, kg/d 38000 (90%) Q, kg/d 30000 (71%) Q, kg/d 23000 (55%) Q, kg/d 18000 (43%) DM, kg/d 2114 (71%) DM, kg/d 533 (18%) DM, kg/d 196 (7%) DM, kg/d (0%) TN, kg/d 123 (87%) TN, kg/d 51 (36%) TN, kg/d 30 (21%) TN, kg/d (0%) Digestate TP, kg/d 49 (71%) TP, kg/d 4 (6%) TP, kg/d 2 (3%) TP, kg/d (0%) Q, kg/d 42000 Screw Centrifuge Ultra Reverse DM, kg/d 2960 Press (decanter) filtration Osmosis TN, kg/d 141 TP, kg/d 69 SP Solid C Solid UF Centrate RO Centrate Q, kg/d 4000 (10%) Q, kg/d 8000 (19%) Q, kg/d 8000 (19%) Q, kg/d 5000 (12%) DM, kg/d 883 (30%) DM, kg/d 1613 (54%) DM, kg/d 307 (10%) DM, kg/d 182 (6%) TN, kg/d 13 (9%) TN, kg/d 58 (41%) TN, kg/d 23 (16%) TN, kg/d 24 (17%) TP, kg/d 16 (23%) TP, kg/d 42 (61%) TP, kg/d 2 (3%) TP, kg/d 3 (4%)

20 Cyprus 2016

Cow manure digestate : 43% volume reduction and water recovery

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University of Verona, Department of Biotechnology

21 Cyprus 2016

SP Liquid C Liquid UF Liquid RO Liquid Q, kg/d 56000 (93%) Q, kg/d 50000 (83%) Q, kg/d 39000 (65%) Q, kg/d 27500 (46%) DM, kg/d 1176 (61%) DM, kg/d 432 (23%) DM, kg/d 270 (14%) DM, kg/d (0%) TN, kg/d 118 (87%) TN, kg/d 86 (64%) TN, kg/d 78 (58%) TN, kg/d 22 (16%) Digestate TP, kg/d 13 (59%) TP, kg/d 7 (32%) TP, kg/d 4 18% TP, kg/d (0%) Q, kg/d 60000 Screw Centrifuge Ultra Reverse DM, kg/d 1920 Press (decanter) filtration Osmosis TN, kg/d 135 TP, kg/d 22 SP Solid C Solid UF Centrate RO Centrate Q, kg/d 4000 (7%) Q, kg/d 6000 (10%) Q, kg/d 11000 (18%) Q, kg/d 10500 (18%) DM, kg/d 920 (48%) DM, kg/d 1122 (58%) DM, kg/d 307 (16%) DM, kg/d 262 (14%) TN, kg/d 18 (13%) TN, kg/d 22 (16%) TN, kg/d 23 (17%) TN, kg/d 56 (41%) TP, kg/d 7,5 (34%) TP, kg/d 9 (41%) TP, kg/d 2 (9%) TP, kg/d 3 (14%)

Piggery digestate: 46% volume reduction and water recovery

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University of Verona, Department of Biotechnology

22 Cyprus 2016

Techno‐economic assessment  Drying process can treat only part of digestate because of heat limitation (partial volume reduction)  Stripping is effective only on part of liquid ammonium and limited by solids presence and nature (colloids). No volume reduction  Membrane processes. High skills required. Good volume reduction (up to 50%) and recovery of water Technical issues:

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University of Verona, Department of Biotechnology

23 Cyprus 2016

Economics

Cost item Dryer Stripping Membrane Capital cost (amortization) 2.51 1.58 2.74 Energy (power) 1.00 1.06 1.85 Chemicals 1.00 1.50 0.33 Labor / service 1.3 0.3 1.05 Total estimated costs 5.81 5.44 6.97

Without considering revenues from nutrients selling or avoided buying

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University of Verona, Department of Biotechnology

24 Cyprus 2016

University of Verona, Department of Biotechnology

Nutrients recovery from anaerobic digestate of agro‐waste: techno‐economic assessment of full scale applications

Department of Biotechnology, University of Verona

University of Verona, Department of Biotechnology

Nutrients are essential for crops growth, that’s why we use mineral fertilisers

University of Verona, Department of Biotechnology

We need nutrients ! 9 billion people Foto Campi …….

University of Verona, Department of Biotechnology

However, nutrients are sometimes scarce ….

University of Verona, Department of Biotechnology

And reserves are in the hands of few Countries ….

University of Verona, Department of Biotechnology

> 8600 AD digestate can be the new mine for EU ! More than 14,000 AD plants wthin EU, 1100 MWel installed

University of Verona, Department of Biotechnology

Anaerobic digestate of agro‐waste can be the new mine

N P K

University of Verona, Department of Biotechnology

University of Verona, Department of Biotechnology

Technologies for nutrients recovery are plenty !

University of Verona, Department of Biotechnology

AD farm plants monitored in this study

University of Verona, Department of Biotechnology

Drying process

University of Verona, Department of Biotechnology

Drying process

University of Verona, Department of Biotechnology

Ammonium sulfate Dryed sludge

University of Verona, Department of Biotechnology

Heat availability is the limiting step: only 20 m3/d

recovery is limited to < 40% of influent N, but around 90% of P in the dryed solids

University of Verona, Department of Biotechnology

Stripper Adsorber Stripping and ammonium sulphate recovery

University of Verona, Department of Biotechnology

Stripping and ammonium sulphate recovery NH3,L NH3,air Liquid w/o NH3 Liquid phase rich in NH3 H2SO4 (NH4)2SO4 (pH  5) NH3,air Qair Warm Air Off gas QL Qair Stripper Ad- sorber Base

University of Verona, Department of Biotechnology

Several key points: fraction of N as ammonium (a), heat, solids removal before stripping

University of Verona, Department of Biotechnology

Membrane processes Digestate Solid to fields Cationic flocculant Liquid

University of Verona, Department of Biotechnology

Solids to fields Centrate Permeate (water) Liquid UF RO

University of Verona, Department of Biotechnology

Cow manure digestate : 43% volume reduction and water recovery

University of Verona, Department of Biotechnology

Piggery digestate: 46% volume reduction and water recovery

University of Verona, Department of Biotechnology

University of Verona, Department of Biotechnology

Economics

Cost item Dryer Stripping Membrane Capital cost (amortization) 2.51 1.58 2.74 Energy (power) 1.00 1.06 1.85 Chemicals 1.00 1.50 0.33 Labor / service 1.3 0.3 1.05 Total estimated costs 5.81 5.44 6.97

Without considering revenues from nutrients selling or avoided buying

University of Verona, Department of Biotechnology

Acknowledgments Thank you for your attention