ECO OGI Pre--treatm ment of o biom mass for f ana aerobiic dige estion Mecha anical prettreatment and separration of organic o wa aste from househollds and industry to obtain a pulp for f biogas sification

Testrreport J.no.1004

Version n 1, Feb 12 2th 2013 Revised version 5, 5 may 6th 2013

Table of conte ents 1.  Intrroduction .................................................................................................................................. 3  1.1.  Name andd contact off proposer .............................................................................................. 3  1.2.  Name of test t centre/ttest responsiible .................................................................................... 3  1.3.  Referencee to test plan n and speciffic verificattion protoco ol .................................................. 3  1.4.  Deviationns to test plaan .......................................................................................................... 3  2.  Tesst design ................................................................................................................................... 3  1.5.  Test site ................................................................................................................................. 4  1.5.1.  Typees of test sitees .......................................................................................................... 4  1.5.2.  Addrresses ...................................................................................................................... 4  1.5.3.  Descrriptions ................................................................................................................... 5  1.6.  Tests ...................................................................................................................................... 5  1.66.1.  Test methods m ................................................................................................................. 5  1.66.2.  Test staff s ........................................................................................................................ 7  1.66.3.  Test schedule s ................................................................................................................. 7  1.66.4.  Test equipment e .............................................................................................................. 7  1.66.5.  Typee and numbeer of samplees ....................................................................................... 7  1.66.6.  Operation condittions ..................................................................................................... 8  1.66.7.  Operation measu urements ............................................................................................... 8  1.66.8.  Technnology maintenance............................................................................................... 8  1.66.9.  Healtth, safety an nd wastes .............................................................................................. 8  3.  Tesst results ................................................................................................................................... 9  1.7.  Test data summary ................................................................................................................ 9  1.8.  Test Perfoormance observation ............................................................................................ 100  1.9.  Test qualiity assurancce summaryy incl. audit results .......................................................... 100  1.10.  Ammenndments to and deviatioons from test plan........................................................... 100  4.  Refferences .................................................................................................................................. 100  Appeendix 1  T Terms and definitions d .......................................................................................... 100  Appeendix 2   Test T data rep port .................................................................................................... 13  Appeendix 3  Amendmen nt and deviaations report for test ........................................................ 344 

2

1. Intrroductio on This tesst report is thhe result off a test carrieed out for verification v of o the perfoormance of an environnmental techhnology folllowing the E ETV metho od. The form mat used forr reporting follows f th guidelinnes in EU geeneral veriffication prottocol versio on 1.0 Decem mber 15 20011. 1.1. Name and co ontact of proposer p Proposeer Komtekk Miljø af 20012 A/S, Drrivervej 8, D DK 6670 Holsted H Contactt: Bjarne Laarsen, phonee: +45 70200 54 89, e-m mail: Bjarne@ @komtek.ddk 1.2. Na ame of tes st centre/te est respon nsible Danish Technologiical Institutee, Verificatiion Centre, Life Sciencce Division,, Kongsvang g Allé 29, DK-80000, Aarhus, Denmark. Test ressponsible: Bjørn B Malmg gren-Hanseen (BMH), phone: p +45 72201810, e-mail: [email protected]. Internall reviewer: Lotte L Bjerru um Friis-Hoolm (LBFH)), phone: +4 45 722018337, e-mail: [email protected] 1.3. Reference to o test plan n and spec cific verification pro otocol The testt plan is titleed: Ecogi, Testplan T J.nno.1004 The verrification protocol is titled: Ecogi, Verification n Protocol J.no.1004 J 1.4. Deviations to o test plan n There w were minor deviations of the methhod in the teest plan for the t sorting pprocedure as a describeed in part 1..10.

2. Tes st design n The testt design is based b on 3 repeated r tes t runs of thee ECOGI fo or each of tw wo differentt kinds of waste inn order to evvaluate the customer cllaims conceerning the fo ollowing isssues: • • • •

R Recovery of o organic matter m for bioogas producction1 in pulp P Purity of orrganic matteer for biogaas production in pulp E Energy connsumption per ton wastee W Water consumption peer ton waste

1

Organicc matter is deffined as materiial which can be converted into biogas within w a normaal period of op peration approx. 225-30 days of mesophilic op peration and 118-21 days of thermophilic operation . W Wood pieces off size >5*5*5 mm are nnot included ass they are not considered diigestible withiin a normal op peration periood in a biogas plant.

3

The twoo types of waste w are: 1. O Organic fracction from household h w waste Vejle Kommune (waste sortiing system). 2. F Food waste from f superm market 25 % %, 25% dairry waste and d 50% of (11)

mbined to Every teest run conssists of 3 baatch runs. Thhe samples taken underr the 3 batchhes are com one testt run samplee (Figure 1). Three tonss waste is processed peer batch.

Figure 1: test runs an nd sampling for f the two waaste types

Calculaation of purrity: Purity oof biopulp iss calculated d as given inn appendix 3 Recovery of biopu ulp: Recoverry of biopullp is calculaated as givenn in append dix 3. 1.5. Tes st site The testt site is Kom mtek A/S, Drivervej D 8, DK 6670 Holsted H 1.5.1. Types of te est sites

The sitee is a plant performing p compostingg operation with a sepaarate treatmeent of organ nic waste using thhe developed ECOGI process. 1.5.2. Addresses s

Test sitte

4

Komtekk Miljø af 20012 A/S, Drrivervej 8, D DK 6670 Holsted H 1.5.3. Descriptions

The EC COGI plant is i placed in a separate cclosed build ding at Kom mtek. All equ quipment in the buildingg including necessary ventilation v iis run by eleectrical pow wer which caan be loggeed separateely from othher facilitiess at Komtekk. 1.6. Tes sts 1.6.1. Test metho ods

Measureement of reecovery and purity is baased on meaasuring all mass m flows during operration of the ECO OGI shown in Figure 2 and analyssis of a num mber of param meters of reepresentativ ve samples taken frrom some off the mass flows. f M2 2 for filling

FT1

M1

M3 forr washing V

Waste e

Fee eder

Pulper

Rejectseparrator/ was hing

M6 Storagetank

FT T2

Pulp for f biogas

M5

M4 Dewatering g

Pure water

Solid fraction

Collectiion of washiing water M7

Figure 2 Mass flows in i test

•

M1 weight

•

ow transmittter) M2 weight (usiing FT1 - flo

•

M3 weight (usiing FT1 - flo ow transmittter)

•

M4 weight willl decrease during d transpport for draainage

5

•

M5 weight will be recorrded after ddrainage, 60 0 liter of the t solid frraction per test run iss sam mpled representatively for f organic ccontent testt

•

M6 weight, reepresentative samplingg of each batch b whilee pumping for test off anorganicc conttent in biopuulp.

•

M7 volume (byy height meaasurement iin tank) befo fore and afteer a test run.. Representative mples will bee taken afterr each test rrun while pu umping the washing waater out of the t sam reseervoir after each e test run n.

The elecctricity consumption iss measured bby reading the electriciity-meter off the hall, th he ECOGI is operaating in, beffore and afteer every testt run. The ECOGI E is th he only operrating mach hine in this hall. Basicallly three testts are perforrmed on thee samples taaken out durring test forr one waste type, see section 0 for detaileed descriptiion of the teests and sam mpling: p purity tesst (sampling position V V) Biopulp y of the bioppulp by sortting the inorrganic residdues out of the t biopulp This tesst determinees the purity sample by sieving the t biopulp, flushing w with warm water w and haand sorting of organic rests r on the sieve. T The inorganiic residue iss dried and w weighed. 5 Organiic content test in solid fraction (ssampling position M 5) This tesst determinees the loss of o organic m matter in the ECOGI pro ocess, whicch is the biop pulp not being w washed of thhe solid fraction in the E ECOGI process. d repeatedlyy on the solid fraction Automaatic washingg in a speciaally designeed washer iss performed followinng filtrationn in order to determine rest organicc matter in the t solid fraaction. The subsampples will bee dried, man nually sortedd for organiic/inorganicc matters annd analysed for dry matter. Organiic content in n washing water (sam mpling posittion V duriing recircuulation of co ontent from coollection tank) This tesst determinees the organ nic residue inn the washiing water. This T test is pperformed fo or mass balance reasons onnly and will not be incluuded as losss of organic material inn our calculaations, becausee the washinng water is recycled r to the pulper in i normal op peration forr reuse in neext pulping step andd thus the coontent of orrganic matteer is not lostt. Solids) is an nalysed from m representaative samplees. The TS (Total Solids) and VS (Volatile S The testt methods are a described d in detail inn appendix 3 of the test plan.

6

1.6.2. Test staff

The testt staff is Bjørn M Malmgren-H Hansen (BM MH) Sabine L Lindholst (S SBL)

S Sampling, data d analysiss and reportting (TI) S Sampling, analyses, a data analysis, reporting (TI)

1.6.3. Test sched dule Task

Timing

Applicatiion definition document

August 20112

Verificatiion protocol with w test plan

November 22012

Test

December 22012

Analysis phase

December 22012-january 2013 2

Test repoorting

January 20113

Verificatiion

January 20113

Verificatiion report

April 2013

1.6.4. Test equip pment

The testt equipmentt includes besides the E ECOGI sam mpling contaainers, buckkets, sieves with w differennt mesh sizees, small wh heel loader, pitch-fork, sorting tablle with drainn for water collection, small shhovels, drying ovens, concrete mixxer with attaached 40 mm sieve, weeights, flow wmeters in plant. For further details d see Appendix A 3 iin the test plan. p 1.6.5. Type and number n of samples

The typpes and num mber of samp ples per typpe of waste are a summarrized in the following. sample

bioopulp solid fraction Collecction tank

Samp pling posittion

Number of batch sam mples

Number N of test sampless

V M5 M V

9

3 3

Nu umber of sam mples per waste type 3 3 3

In generral the folloowing practiise for samppling, subsaampling and d sample hanndling of su uspensions was useed. Samplin ng of main n sample fro om inlet an nd outlet The maiin samples are taken frrom valves w with sufficiient dimensiion (1”) to eensure that no materiall is stuckk in the valvve. Before obtaining tthe sample at least 2 litres are disscarded. A 10-15 litree bucket iis used for sampling s the main sam mples. For deetails see Ap ppendix 3 in Test plan. bsamples Preparaation of sub In all suubdividing of o samples care was taaken to prod duce represeentative subbsamples as some fibree materiall may float or sink.

7

Dependding on typee of the hom mogeneity oof the biomaass pulp thee subsamplees were obtaained in thee followinng way: 1) H Homogenioous pulps: a subsamplee was madee by stirring main sampple well during transferr tto subsample 2) IInhomogen nious pulpss with floatiing layers or o fast sink king layers: Sieving off fibres wass pperformed followed f by y proportionnal weigh off solid and liquid l fractiions into sub bsamples. Used M Methods In the teests the bioppulp was veery homogennious and could be sub bsampled ussing method d 1). This method was also ussed for wash hing water iin the sortin ng step. All otheer sampled material m waas solid. Handlin ng of samp ples All fibrre material was w refrigerrated if testts were perfformed with hin 2-3 dayys or freezeed down forr later anaalysis. Used prreservation and storag ge of samplees: Solid fraction sampples were transported too Danish Teechnologicaal Institute ddirectly and d dried there beefore VS analysis.

1.6.6. Operation conditions s

Before eeach test run of waste, the whole ssystem was flushed witth clean watter until no visible rest from thee previous operation o co ould be obseerved any lo onger. Furth her all convveyers for so olid input and outpput waste was w emptied d. Each batchh test uses 30 3 minutes pulping. 1.6.7. Operation measurem ments

• •

T Total powerr consumptio on during trreatment waas recorded W Water consuumption durring treatmeent was reco orded

1.6.8. Technolog gy maintenance

The testt is a short term t perform mance test oof 2-3 days.. Maintenan nce requirem ments are no ot covered in the teest. 1.6.9. Health, saffety and wa astes

p weears a protecctive suit an nd gloves, saafety glassees in case th here is risk While teesting, the personal of splasshes and if necessary n brreathing prootection. Th he waste can n be depositted in a general waste containeer. Based onn low tempeeratures durring test (0-5ºC) it was decided thaat sorting co ould be perform med without breathing protection. p

8

3. Tes st results s The testt report willl be included as an app endix in thee verificatio on report acccording to the t DANET TV Centre Quality Q Man nual. 1.7. Tes st data su ummary Target aand measureed values off tested paraameters. For the following types t of wasste the perfoormance parrameters in the table beelow were obtained: o mmune wasste sorting ssystem. A: Orgaanic fractionn from houssehold wast e Vejle Kom B: Foodd waste from m supermark ket 25 %, 2 5% dairy waste w and 50 0% of (A) Parameeters Overall performancce Capacityy Chemiccals Pure Waater

Target T

Energy Electriciity consumption Treatm ment effects Purity of pulps (nondegradable particless plastic, glas, metal of 2-6 mm)) % in a pulp with w DM 15% Recoverry % VS

95 9 %

90 9 %

Meaasured value

Method/com mment

5-6 ton organic waste w /h Nonne apprrox. 1 ton watter/ton wet wasste

Based on tesst.

20-330 kwh/ton waaste

based on connsumption in the tests

Based on tesst.

Testt with A >99..86 % in pulpp with 15% TS S Testt with B >99..96 % in pulpp with 15% TS S Testt with A: 94.8 8 % with stanndard deviation n of 0.7 % Testt with B: 95.9 9 % with stanndard deviation n 0.6 %

9

It is conncluded for ECOGI sysstem: • tthe purity of o pulp is hig gh (>99.8 w weight %) when w measurring the conntent of plasstic, glass eetc. >2 mm m) • tthe recoveryy is high (ap pproximate ly 95% of the t organic waste w is reccovered in th he pulp in tthe two testts) 1.8. Tes st Perform mance obs servation The testt was designned to test the ECOGI equipment performancce under reaalistic operaating conditioons and withh two differrent sorts off waste. By choosing th he amount oof replicate operating cycles uused in the test, t the dataa observed ccan be judg ged as being g representat ative for most operatioons of the eqquipment. The plannt operated well with no n accidentiial operation n stops duriing the 2 day ay test 1.9. Tes st quality assurance summarry incl. au udit results s For eachh batch run mass balan nces were caalculated to validate thee measuredd mass and flow f measureements. Furrther mass balances b weere made forr the sorting g and washinng procedure to validatee the accuracy of the method. 1.10. Ammend dments to and devia ations from m test plan n The testt plan was followed f exccept from m minor adjusttments in th he sorting prrocedure The folllowing deviiations weree made from m the test pllan: r fractioons was perrformed direectly after w washing (wiithout The hannd sorting of the solid reject drying) as this was judged a more m secure sorting metthod becausse it was moore easy to recognize r getables likee carrots wh hich loose co olor and forrm when dry ying). the orgaanic materiaals (etc. veg The orgganic fractioons from 2 - 40 mm weere not crush hed in the ch hain crucheer, because there t was not enouugh materiaal for the ch hain crucherr to work. In nstead parts of the sorteed out organ nic materiall was crushed in a mortar for subssampling.

4. Refferences s Appendix 1 Term ms and deffinitions Terms aand definitioons used in the protocool are explaiined in Tablle 4.1. Table 4.11 Terms and definitions used by the DA ANETV test centres.

100

Word

DA ANETV

Com mments on the DAN NETV app proach

Analyticaal laboratoryy

Inddependent anallytical laborattory useed to analyse test t samples

The test centre maay use an ytical laborato ory as analy subccontractor

Applicatiion

Thee use of a prod duct specifiedd with resppect to matrix x, target, effectt and lim mitations

The application must m be definedd h a precision th hat allows the with user of a product verification v too judge whether his needs are comp parable to the verification cond ditions

DANETV V

Dannish centre for verification of envvironmental teechnologies

(DANET TV) test centre

Preeliminary nam me for the verrification bodies in DANET TV witth a verificatio on and a test su subboddy

Nam me will be chan nged, when thhe finall nomenclaturee in the EU ET TV has been b set.

Effect

Thee way the targ get is affected

The effect could be b concentratioon uction, decreasse in treatmentt redu perio od, pH increasse etc

(Environm mental) product

Reaady to market or prototype stage prooduct, process,, system or ser ervice bassed upon an en nvironmental techhnology

The product is thee item produceed and sold s and thus the item that a vend dor submit for verification

Environm mental technologgy

plication of Thee practical app knoowledge in thee environmenttal area

The term technolo ogy is coveringg a varieety of products, processes, systeems and servicces.

Evaluatioon

Evaaluation of tesst data for a techhnology produ uct for perform mance andd data quality

None

Experts

Inddependent perssons qualifiedd on a techhnology in veerification

Thesse experts may y be technicall expeerts, QA experrts for other ETV V systems or reegulatory expeerts

Matrix

Thee type of mateerial that the prooduct is intend ded for

Matrrices could be soil, drinkingg wateer, ground watter etc.

Method

Genneric documen nt that provide des rulees, guidelines or characterisstics

An in n-house method may be useed in th he absence of a standard, if

11

Word

DA ANETV

Com mments on the DAN NETV app proach

for tests or analy ysis

prepared in complliance with thee form mat and conten nts required foor stand dards.

Performaance claim

Thee effects foresseen by the veendor on the target (s) in i the matrix oof inteended use

None

Performaance parameters

Parrameters that can c be docum mented quaantitatively in tests and thatt proovide the relev vant informatioon on the performance of an envvironmental teechnology prooduct

p mu must The performance parameters be esstablished con nsidering the appliication(s) of th he product, thhe requ uirements of so ociety (regu ulations), custtomers (needs)) and vendor v claimss

Proceduree

Dettailed descripttion of the usee of a stanndard or a method within onne boddy

The procedure speecifies impllementing a standard or a meth hod in terms of o e.g.: equip pment used

Producer

Thee party produccing the produuct

None

Proposer

Anyy legal entity established inn or outtside the Europ pean Union preesenting an inn novative envvironmental teechnology for verrification undeer the EU ETV V pilot proogramme

None

Standard

Genneric documen nt establishedd by connsensus and ap pproved by a recognized stand dardization bo dy thatt provides rulees, guidelines or chaaracteristics fo or tests or anallysis

None

Target

Thee property thaat is affected bby the prooduct

Targ gets could be e.g.. e contaminnant conccentration

Test centtre, test sub-bodyy

Subb-body of the test centre thaat planns and perform ms test

None

Test centrre, verificatioon subbody

Subb-body of the test centre thaat planns and perform ms the verific ation

None

Test/testinng

Dettermination off the performaance of a product for parameters p deefined

None

122

Word

DA ANETV

Com mments on the DAN NETV app proach

for the applicatio on Vendor

Thee party deliverring the produuct to the customer

Can be the produccer

Verificatiion

Evaaluation of pro oduct perform mance parrameters for a specified appplication under defined connditions and ad dequate qualitty assuurance

None

Appendix 2

Test data re port

Test The testt was perforrmed as desscribed in thhe test plan except mino or deviationn in sorting method (see 3.44). Before tthe actual teest, a prerun n was perforrmed on 10.dec 2012 for f testing thhe method and a calibratiing the equiipment. Calibraation All weigghts used were w calibratted using prreweighed calibration c bottles b withh water (129 9.08 g and 4.46 kg)) which werre weighed using DTIss calibrated laboratory weights. w Table 2 T Test results

Weight small w weight (g) 20 kg w weight (kg) 30 kg w weight (kg)

referencee 129.08 4.46 4.46

measuredd 129 4.45 4.4

All weigghts measurred within the t accuracyy of reading g. The inpput amount of o added waaste and thee output amo ount of reject was weigghed using calibrated c weighinng cells on Komteks K wh heel loader.. Calibrattion of flow w transmitterrs was perfoormed by ussing the bassin M7 for m measuring th he amount. The area of the bassin was meaasured to 1.44*11.7 = 16 6.38 m2.

133

Table 3 T Test of flow transmitter FT1 by addingg of water performed dec..10th 2013

test added FT T1 (m3) measured ((cm) Calcculated addiition (m3) Differen nce % 1 6.1 39 6.39 9 -4.5 2 2.4 14.8 2.42 2 -0.8 The resuult is accepttable within n the uncertaainty of heiight measurement of thhe basin (1 cm) c and area meeasurement (1 cm heigh ht corresponnds to a volu ume changee of 0.164 m m3). Sortingg test Based oon the preruun it was deccided to runn without the chain crussher, becausse there wass not enough material for the chain crucher to w work. pection of thhe waste it was decided to perform m the hand sorting s of Based oon drying triials and insp the solidd reject fracctions directtly after wasshing witho out drying as this was juudged a mo ore secure sorting m method as materials m were more eaasily recogn nized.

Tests peerformed Tests w were perform med 11.deceember usingg organic waaste collecteed from houuseholds in Vejle and on 12.deecember using 50 % waste w from V Vejle and 50 0% waste frrom industryy. The testt included thhe following steps accoording to test plan: • Recording all input and output weigghts as welll as power consumption c n for each teest run • Saampling of produced pu ulp o anallysis of VS and TS of ppulp o anallysis of puriity of pulp ((amount of non-degrad dable matterr > 2 mm – glass, metal, plastic) by b washingg, sorting an nd weighing • Saampling of reject nic waste o subssampling off reject for ttesting content of organ o washing of subsample in sspecial mach hinery o sorting reject in n non-degraadable matteer (plastic, metal, m glasss/stones) and d degrradable mattter and weiighing (wet)) o dryiing subsamp ples of sorteed reject and d weighing for dry mattter analysiss o Anaalysis of Volatile solidss content (orrganic matter) Documeentation phootos from seelected indiividual steps in the test are shown below. Samplin ng of produ uced pulp 3 subsam mples weree taken durin ng pumpingg to storage tank and traansferred too a large buccket for mixing and subsam mpling whilee stirring.

144

Figure 3 Sampling off pulp

Analysiis of purity of pulp A 1 litree subsamplee of the pulp p was washhed on a 2 mm sieve as shown beloow before collection off particless for dryingg and weigh hing.

Figure 4 Washing of pulp p to estim mate purity

155

Samplin ng of rejectt The rejeect was colllected in a container c wiith drainagee of water to o floor tank.. The contaiiner with one batcch was transsferred to a clean storaage facility for f mixing and a weighinng.

Figure 5 Collection off reject from one batch in container

The 3 batches in a test run werre mixed ussing a large wheel loader and weigghed using the t weighinng cells of thhe wheel loader

Figure 6 Mixing of 3 batches b to on ne sample rep presenting a test t run and weighing w withh wheel loadeer

166

From thhe mixed 3 batches b a reepresentativve sample was w taken by y using a graab randomly y picking and filliing a 60 litre square bu ucket. The squuare bucket was now so orted accordding to the procedure p in n appendix 3 of the testt plan. The conntent was weighed and transferredd to a cemen nt mixer with a 40 mm screen in frront togetherr with washhing water (F Figure 7). T The averagee weight was approxima mately 15 kg for each wash. T The amount was washed d in three stteps while rotating. r The useed sorting prrocedure (ap ppendix 3, ttest plan) iss summarizeed below 1: washhing with 488 litre cold water w for appprox. 10 miinutes, decaanting of waater by tiltin ng into a collectinng bucket with w a 10 mm m screen 2: washhing with 200 litre cold water w for appprox. 10 miinutes, decaanting of waater by tiltin ng into a collectinng bucket with w a 10 mm m screen 3: washhing with 200 litre hot water (30-40ººC) for apprrox. 10 minutes, decant nting of wateer by tiltingg into a coollecting buucket with a 10 mm scrreen (Figuree 8) 4: remooval of >40 mm m reject for f sorting 4aa: The rejecct fraction >40 mm wass hand sorteed in non-deegradable m material (plastics, m metal, glass, bones and sticks s with ddimensions larger than n 5*5*5 mm m and organiic material (F Figure 10) 4bb: The mateerial was weeighed (wet)) 4cc: The non-oorganic matterial was ddried and weeighed 5: The < 10 mm fraaction inclu uding washinng water waas filtered on o a 2 mm sscreen (Figu ure 9). The amount was small and a it was sorted s togethher with thee 10-40 mm m fraction. 6: remooval of 2 - 400 mm rejectt for sortingg 6aa: Sorting a representattive sample of approx. 20% of the reject fracttion 2 - 40 mm m by haand in non-ddegradable material (pllastics, metal, glass, bo ones and sticcks with dim mensions laarger than 5**5*5 mm an nd organic m material (Fiigure 11) 6bb: The mateerial was weeighed 6cc: The non-oorganic matterial was ddried and weeighed 7: From m the organicc fraction > 40 mm andd 2 - 40 mm m proportion nal subsampples were prrepared by thorouggh mixing foor analysis of o TS and V VS. 8: Samppling of wasshing water A representative saample was taken from w washing waater to furtheer analysis oof TS and VS V

177

Figure 7 Washing in cement c mixerr with 40 mm m screen

Figure 8 Collection off 10 - 40 mm reject from w washing

188

Figure 9 Collection off 2 - 10 mm reject from w ashing

Figure 100 Sorting of > 40 mm washed reject fraaction

199

Figure 111 Hand sortin ng of 2-40 mm m fraction on n sorting tablle

Total Soolids and Volatile V solid ds analysis TS and VS was anaalyzed on organic sampples that weere manually y homogeniized as thorroughly as possiblee by using a mortar. The dryying methodd for organicc fraction ussed was 103 3 °C for 4 days, d as therre still was loss l of weight aafter 2 and 3 days. Thee low tempeerature optio on in test plan appendixx 3 (50 °C) was not used, ass the drying would havee been too ttime consum ming.

200

Test ressults and Mass M Balancces were record During all tests thee following parameters p ded as show wn in Table 4 to Table 9. • Innput of wastte (waste in ton) T The amount was only weighed w forr the sum off 3 batch tessts and thereefore has beeen ddistributed evenly betw ween the 3 bbatch tests • A Amount of water w to pulp per T The amount is added using u FT1 • Tootal water for f Reject seeparation T The total am mount for reeject separaation was meeasured by reading amo mounts added d by flow ttransmitterss. This amou unt is transfferred to thee pulp in thee rejection sstep. • Puulp to storagge tank T The amount is measureed using FT T2 • W Washing watter T The washinng steps is divided d in 2 steps with approx. a 1.5 m3 in first sstep using technical t w water follow wed by 2.3 m3 fresh waater • Reject T The amount was only weighed w forr the sum off 3 batch tessts and thereefore has beeen ddistributed evenly betw ween the 3 bbatch tests • Poower consum mption T The power consumptio on of the plaant includin ng ventilatio on was recorrded by reading the kkWh counteer before an nd after the combined 3 batch testss in each tesst run

21

Table 4 T Test A test ru un T1 11.dec.113 A‐T1 

bbatch 1 

Waste in nput ton 

batcch 2 

batch 3  b

Sum m or average  

2.233

2.233

2.233

6.7 7 

3

2

2

2

6  6

Water leevel after wateer addition (cm) 

86

104

Amount of water added to pulper ((m ) FT1  Reject seeparation 

 

Total sep paration wateer added to pu ulp  3

Pulp to sstorage tank m m  FT2  Washingg  3

Pure watter for washin ng m  

Mass baalance 

  

6.7

6.5

19.7 7 

9.3

9.2

9.5

28 8 

  

 

  

1.5

1.5

1.5

4.5 5 

2.3

2.3

2.5

7.1 1 

 

Reject out ton 

 

6.5  

other waater washing ((estimated) *  Reject out 

  

130   

   0.48

 

  0.48

  

   0.48

 

1.45 5    

Input waaste + water 

10.73

10.93

10.73

32.40 0 

Output p pulp + reject 

9.78

9.68

9.98

29.45 5 

error in mass balance % 

8.85

11.43

6.99

 9.1 1 

kWh beffore 

253515   

 

  

kWh afteer  

 

  

253709   

Power co onsumption kkWh 

 

  

194   

b A-T T1, batch 1: Examplle calculatioon of mass balance Input w waste and waater = 2.23 + 2 + 6.5 = 10.73 ton Output ppulp and rejject = 9.3 + 0.48 = 9.788 ton

222

Table 5 T Test A test ru un T2 11.dec.113 A‐T2 

battch 1 

Waste in nput ton  3

Amount of water added to pulper ((m ) FT1  Water leevel after wateer addition (cm)  Reject seeparation 

batch h 2  2.3 333

2.333 3

7 

2

2

2

6 

   3

Pulp to sstorage tank m m  FT2 

  

  

  

  

  

7

6.1

6.55 5

19.65 

9.3

8.7

8.4 4

26.4 

Washingg 

    

other waater washing  3

Pure watter for washin ng m   Reject out 

2

1.65 5

4.95 

2.3

2.3

2.3 3

6.9 

   0.52

Mass baalance 

    

1.3   

Reject out ton 

Sum or aveerage 

2.333 104   

Total sep paration wateer added to pu ulp 

batch 3

  

   0.52 0

  

   0.52 2

  

1.55    

Input waaste + water 

11.33

10 0.43

10.88 8

32.65 

Output p pulp + reject 

9.82

9.22 9

8.92 2

27.95 

13.38

11 1.66

18.07 7

 14.4 

error in mass balance %  kWh beffore 

2 53752   

  

  

kWh afteer 

  

  

253922 2   

Power co onsumption kkWh 

  

  

170 0   

battch 1 

batch h 2 

Table 6 T Test A test ru un T3 11.dec.113 A‐T3  Waste in nput ton  3

Amount of water added to pulper ((m ) FT1 

batch 3

Sum or aveerage 

2.167

2.167

2.167 7

6.5 

2

2

2

6 

Water leevel after wateer addition (cm) 

  

  

  

  

Reject seeparation 

  

  

  

  

Total sep paration wateer added to pu ulp 

6.8

3

Pulp to sstorage tank m m  FT2  Washingg 

9.5   

other waater washing  3

Pure watter for washin ng m   Reject out 

6.6 6

9.5   

19.8 

9.4 4   

28.4    

1.4

1.5

1.3 3

4.2 

2.3

2.3

2.3 3

6.9 

  

Reject out ton  Mass baalance 

6.4

   0.49

  

   0.49 0

  

   0.49 9

  

1.46    

Input waaste + water 

10.97

10 0.57

10.77 7

32.3 

Output p pulp + reject 

9.99

9.99 9

9.89 9

29.86 

error in mass balance % 

8.94

5.49 5

8.17 7

 7.55 

kWh beffore 

2 53922   

  

  

kWh afteer 

  

  

254086 6   

Power co onsumption kkWh 

  

  

164 4   

233

Table 7 T Test B test ru un T1 12.dec.113 B‐T1 

battch 1 

Waste in nput ton  3

Amount of water added to pulper ((m ) FT1  Water leevel after wateer addition (cm)  Reject seeparation  Pulp to sstorage tank m m  FT2 

2.267 7

6.8 

2

2

2

6 

3

Pure watter for washin ng m   Reject out 

  

  

   7.4 4

19.9 

10.9

8.4

10 0

29.3 

  

  

  

1.2

2.8

1.1 1

5.1 

2.3

2.3

2.3 3

6.9 

   0.53

Mass baalance 

  

5.6

  

Reject out ton 

  

6.9   

other waater washing 

Sum or aveerage 

2.2 267

   3

batch 3

2.267 104.5   

Total sep paration wateer added to pu ulp  Washingg 

batch h 2 

  

   0.53 0

  

   0.53 3

  

1.6    

Input waaste + water 

11.17

9.87 9

11.67 7

32.7 

Output p pulp + reject 

11.43

8.93 8

10.53 3

30.9 

error in mass balance % 

‐2.39

9.46 9

9.71 1

 5.5 

kWh beffore 

0

kWh afteer 

  

2543 399      

   254493 3   

Power co onsumption kkWh        141* *    * for this test the poweer consumption n for the test run was calcu ulated from tw wo batch runs Test B test ru un T2 Table 8 T 12.dec.113 B‐T2  h 2  batch 3 Sum or aveerage  battch 1  batch Waste in nput ton  Amount of water added to pulper ((m3) FT1 

2.783

2.7 783

2.783 3

8.35 

2

2

2

6 

Water leevel after wateer addition (cm) 

  

  

  

  

Reject seeparation 

  

  

  

  

Total sep paration wateer added to pu ulp  3

Pulp to sstorage tank m m  FT2  Washingg 

7.1 1

21.1 

10

9.9

10.6 6

30.5 

   1.3

3

Pure watter for washin ng m  

   1.3

2.3   

Reject out ton  Mass baalance 

7

  

other waater washing  Reject out 

7

0.50   

1.2 2

2.3   

   2.3 3

   0.50 0

  

3.8  6.9    

0.50 0   

1.5    

Input waaste + water 

11.78

11 1.78

11.88 8

35.45 

Output p pulp + reject 

10.50

10 0.40

11.10 0

32 

error in mass balance % 

10.89

11 1.74

6.59 9

 9.73 

kWh beffore 

2 54538   

  

  

kWh afteer 

  

  

254693 3   

Power co onsumption kkWh 

  

  

155 5   

244

Table 9 T Test B test ru un T3 12.dec.113 B‐T3 

battch 1 

Waste in nput ton 

Reject seeparation 

  

2.633 3

7.9 

2

2

2

6 

  

3

To storage tank m  FTT2 

3

Pure watter for washin ng m  

21 

10

9.8

9.8 8

29.6 

  

  

1.3

1.3

1.3 3

3.9 

2.3

2.3

2.3 3

6.9 

   0.54

Mass baalance 

   7

  

Reject out ton 

   7

  

other waater washing 

  

7   

Reject out 

  

  

Total sep paration wateer added to pu ulp  Washingg 

Sum or aveerage 

2.6 633

Amount of water added to pulper ((m ) FT1    

batch 3

2.633 3

Water leevel after wateer addition (cm) 

batch h 2 

  

   0.54 0

  

   0.54 4

  

1.62    

Input waaste + water 

11.63

11 1.63

11.63 3

34.9 

Output p pulp + reject 

10.54

10 0.34

10.34 4

31.22 

9.40

11 1.12

11.12 2

 10.5 

error in mass balance %  kWh beffore 

2 54706   

  

  

kWh afteer 

  

  

254877 7   

Power co onsumption kkWh 

  

  

171 1   

The calcculated masss balances for the 3 tessts have aveerage errorss between 5 and 14 weiight %. The erroor may be due d to an errror in readinng of FT2 of o approximately -10 % or a combiination of reading errors in FT T1 and 2. Itt was not prractically po ossible to caalibrate the fflow transm mitter FT2 on the ppulp. Table 10 shows waaste in- and -outputs annd power co onsumption for each tesst run. Table 100 Waste amou unts and power consumptiion

Test  teest run  A  1  A  2  A  3  B  1  B  2  B  3 

ut waste  Output Pulp  O Output re eject  Inpu kWh u ton (wet)  to on(wet)  ton (wet) used  kWh//ton input wet  288 6.70  1.45 194 29.0 2 26.4 4 7.00  1.55 170 24.3 2 28.44 6.50  1.46 164 25.2 2 29.33 6.80  1.6 141 20.7 2 30.55 8.35  1.5 155 18.6 1 29.66 7.90  1.62 171 21.6 2

The watter consumpption of purre water is aat present un nder improv vement. In nnormal operration technicaal water (reccycled from m earlier pullpings) is ussed for new pulpings. T The technicaal water is produceed by dewattering of thee pulp by a ddewatering technology y which is prresently beiing optimiseed. Based on o the test 2.3 ton of puure water waas needed fo or washing the reject of o each batch w which is apprroximately the same ass the added amount of wet w waste.

255

Analyysis resu ults Purity In Figurre 12 the coontent of ressidue (2-6 m mm) in 1 litter pulp from m the purityy analysis is shown.

Figure 122 Inorganic dried residuee (2 - 6 mm) oof 1 liter pulp p from test ru uns

T purity iis recalculatted to 15 % The table below shhows the anaalysis data ffor calculatiing purity. The TS as thhis is the typpical producct quality affter dewaterring using a screw presss. Test  teest  run  A  A  A  B  B  B 

11  22  33  11  22  33 

biopulp  weigh hed  (g)  1000.00  1000.00  1000.00  1000.00  1000.00  1000.00 

TS pullp % 

4.99  5.88  6.13  6.41  6.93  6.8 

TSS inorganic  coomponents  2  ‐ 66 mm (g)  0..4555  0..7909  0..3125  0..1623  0..1969  0..1958 

nic  % inorgan in pulp  0.05  0.08  0.03  0.02  0.02  0.02 

% inorrganic in  pulp w with 15%  DM  0.14  0.20  0.08  0.04  0.04  0.04 

The imppurities >2 mm m amountts to 266

A averaage: 0.14 % standard deeviation 0.006 % B averaage: 0.04 % standard deeviation 0.0 02 % when n recalculateed to 15 % T TS. The parrticles have to pass a 6 mm sieve inn the rejectiion separato or and thereefore cannott be larger.

The purrity (amountt of non-deg gradable maaterial like plastics, p glaass and metaal) are A > 99.86 % B > 99.996 % in a pulpp with a callculated TS of 15 wt % Recoverry The table below shhows results from weighhing of the reject samp ples. The sam mples weree treated accordinng to the prrocedure usiing washingg and hand sorting s of frractions largger than 40 mm and from 2 - 40 mm. Thhe hand sorrting producced a numbeer of fractio ons which arre nondegraadable in biogasiffication andd organic fraactions whicch are degraadable in biogasificatioon. Further the t washingg water conttained particles and sollubilized orrganics < 2 mm. m In the soorting proceedure the material m is diivided into : Non deggrable fractions in biog gasification including: • M Metal • Pllastic, rubbeer and textilles • otther inorgannic materials like stone s ,ceramics and glass • w wood pieces,, sticks and bones with dimensionss >5*5*5 mm m Fractionns degradabble in biogassification inncluding: • orrganic wastee from housseholds andd industry

277

Table 11Weighing of reject       Non‐degraadable in  Degradable in D n  biogasification  (kg  bio ogasification ((kg  wett)  wet)  Test 

A  A  A 

Sample  wash  Drained reject  D   water  input  after washing  a    > 40 mm  teest  (kg  input (kg)  (kg wet)  ru un  wet)  79  15.1  11  17.42  9.27  76  14.1  22  17.49  6.82  75  14.1  33  17.10  4.76 

2 ‐ 40  mm 

> 40  > mm  m

2 ‐ 400  mm m 

wash watter  drained o off  organic  (kg)  wet (%) 72.60  29.3 

3.01 

0.52  0

4.577 

4.54 

0.26  0

4.655 

72.10 

30.2 

4.60 

0.29  0

5.744 

73.30 

39.2 

B 

11 

10.95 

75 

12.70 

5.24 

3.03 

0.29  0

2.799 

70.60 

27.1 

B 

22 

13.95 

75 

15.20 

6.18 

3.16 

0.48  0

3.122 

73.30 

27.8 

B 

33 

13.1 

79.5 

16.52 

5.02 

4.30 

0.38  0

4.566 

72.53 

34.6 

The weiights for 2 - 40 mm aree based on ssorting and weighing w of 20 % of thhe wet samp ple. orting. There iss a minor looss of water during draiinage and so The mass balance of o input (before washinng) and outp put (after washing) shoows the follo owing deviatioons. Figure 133 Mass balan nce before and d after washiing

testrun  A  A  A  B  B  B 

batch  1  1 2 2  3 3  1 1  2 2  3 3 

input  output  ddeviation % 94.10  89.97 ‐4.4 90.10  88.37 ‐1.9 89.10  88.69 ‐0.5 85.95  81.94 ‐4.7 88.95  86.24 ‐3.1 92.60  86.78 ‐6.3

0 -6 % is acceptable a w when taking g into accou unt the largee number off operations The watter loss of 0.6 in the soorting proceedure. An exam mple of the sorted fracttion > 40 m mm, textile and a plasticss is shown inn Figure 14 4. In Figurre 15 the noon plastic an nd textile coontent in a >40 > mm sorting fractionn is shown.

288

Figure 144 Sorted fracction >40 mm m textile and p plastics

Figure 155 Sorted fracction >40 mm m metal, organ nic residue an nd non biogas degradablee woodsticks and a bones

An exam mple of the sorted fracttion 2 - 40 m mm is show wn in Figuree 16 to Figurre 18

299

Figure 166 Sorted fracction 2-40 mm m organic fraaction

Figure 177 Sorted fracction 2-40 mm m plastic fracction

300

Figure 188 Sorted fracction 2-40 mm m textile, met als, bones an nd sticks

The conntent of stickks, bones with w dimensiions >5*5*5 5 mm was measured m inn test B. Theese are not considered to be deegradable in n biogasificaation withou ut severe prretreatment which is yeet not developped or installled at full scale s biogass plants. 2% of the orrganic food waste (wett weight) or between 2--3.3 % of The conntent was beetween 6-12 the totall amount off sorted wasste (Wet weiight). S and Volatile V soliids of the so orted organiic fractions and the wasshing waterr In Tablee 12 Total Solids are show wn.

31

Table 12 TS and VS of o organic con ntent in fracttions

Biopulp p  A  A  A  B  B  B  Reject 22‐40  mm  A  A  A  B  B  B  Washing  water  A  A  A  B  B  B 

Standaard  Standard d  testt run  TS %  dev. % %  VS %  dev. %  1  4.99  4 0 .52 88.4 43 0.17 7 2  5.88  0 .44 88.4 48 0.09 9 3  6.13  0 .06 88.3 36 0.92 2 1  6.41  0 .09 90.3 33 0.66 6 2  6.93  0 .11 90.4 42 0.61 1 3  6.80  0 .11 90.2 27 0.46 6

1  2  3  1  2  3 

14 4.49  15.63  15.38  14 4.71  15.10  15.36 

1 .12 0 .16 0 .62 0 .09 0 .51 0 .45

81.3 37 83.3 37 90.6 60 87.0 05 92.2 26 87.8 84

4.15 5 4.61 1 3.09 9 0.24 4 1.89 9 5.05 5

1  2  3  1  2  3 

0.16  0.17  0.22  0.18  0.14  0.15 

0 .00 0 .01 0 .01 0 .01 0 .00 0 .00

69.6 63 74.8 86 73.8 84 74.2 25 73.6 66 76.6 60

0.53 3 2.16 6 1.96 6 2.72 2 2.67 7 2.06 6

Table 13 and Tablee 14 show calculations of recovery y.

322

Table 13 Results for test t A

Test run n  11  2 3  Biopulp p tons Input  28 26.4 28.4 TS %  4.99 5.88 6.13 VS %  88.43 88.48 88.36 Biopulp p VS ton Inpu ut  1.23 1.37 1.54 Reject ttons  1.45 1.55 1.46 Organicc % (wet)  29.30 30.18 39.16 Organicc ton (wet)  0.42 0.47 0.57 Organicc DM %  14.49 15.63 15.38 Organicc VS %  81.37 83.37 90.60 Organicc VS ton exclu uding washin ng water  0.050 0.061 0.080 Organicc VS ton inclu uding washin ng water  0.057 0.070 0.091 % recovvery  95.41 94.93 94.07

on = 0.68 % % recovvery for testt A: 94.8 % with standaard deviatio Examplle calculatioon T1: Biopulpp in VS = 288 * 4.99 * 88.43/100/10 8 00 = 1.23 to on Organicc reject wet = 1.45 * 29 9.3/100 = 0..42 ton Organicc reject exclluding wash hing water V VS ton = 1.4 45*29.3/100 0*14.49*811.37/100/100=0.050 ton Washinng water adddition T1 Input = 17.42 kg orrganic wet content c 0.522 + 4.57 = 5.09 5 kg with h DM 14.499% VS = 81 1.37% washingg water = 722.6 kg with TS = 0.16% % VS = 69.6 63% 49*81.37/1 00/100 = 0..60 kg Organicc content (exxcl. washing water) in VS = (0.52+4.57)*14.4 Organicc content waashing wateer in VS = 772.6*0.16*6 69.63/100/10 00 = 0.081 kg Thus foor T1 we havve additionaal 50 *0.0811/0.6 = 6.75 5 kg VS to the t 50 kg exxcluding waashing water orr in total 0.0057 ton VS in the rejecct As the bbiopulp conntains 1.23 ton VS the rrecovery forr batch 1 can be calculaated to (1.23 30.057)/11.23*100 = 95.4%.

333

Table 144 Results for test t B

Test run n  Biopulp p tons Input  TS %  VS %  Biopulp p VS ton Inpu ut  Reject ttons  Organicc % (wet)  Organicc ton (wet)  Organicc TS %  Organicc VS %  Organicc VS ton exclu uding washin ng water  Organicc VS ton inclu uding washin ng water  % recovvery 

11 

2 29.3 6.41 90.33 1.70 1.6 27.13 0.43 14.71 87.05 0.06 0.07 95.96

3  30.5 6.93 90.42 1.91 1.5 27.80 0.42 15.10 92.26 0.06 0.07 96.49

29.6 6.80 90.27 1.82 1.62 34.62 0.56 15.36 87.84 0.08 0.09 95.31

% recovvery for testt B: 95.9 % with standaard deviatio on = 0.6 % Discusssion and conclusion The resuults show • a high purity of the prod duced pulp w with less thaan 0.14% paarticles of pplastic, glasss, metal llarger than 2 mm. • a recovery >994.8% of orrganic materrial The organic maaterial will be b in the forrm of food waste w from householdss. Based on the high i partly dow wnsized in tthe pulping process to recoovery it is exxpected thatt the organiic material is allow w most of the material to pass the 6 mm screeen holes in the sorting unit. Looseely bound papeer like dryinng paper forr kitchen usse is also expected be disintegrated d d by the pullping proccess and no identifiablee larger partts of paper was w found in sorted fraactions. Som me sticks and bones and d wood piecces are too solid s to be down d sized in the proceess and are rem moved with the t reject. The T amount of these parrts was limiited in the teests but willl of course depeend on the composition c n of collecteed waste. Appendix 3 Ame endment and a deviattions repo ort for testt No ameendments annd deviation ns are descriibed here (d deviations to o test plan aare given in n part 3.4)

344