1. No category

ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Workshop 25 Oct 2011 :
How to tap the waste to energy potential in the Indonesian agro industry
Residues to Revenues :
How to make money from waste
presented by
Mr. Christoph Kwintkiewicz,
Director ANNIES Export NZ Ltd
New Zealand
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Introduction
Consulting in energy efficiency and biomass usage for over 15 years.
heating systems
 heat demand of buildings
 heat pumps
 air conditioning
 cooling systems
 combined heat and power CHP, Tri-Generation
 lighting systems
 electrical drives
 energy management
 energy from biomass (wood, waste + biogas)

Other trainer activities:
 Decentralized EM
 Communal EM
 Facility Manager
 Solateur + interactiv CD
Trainings done in Germany, Thailand, China
http://www.energymanager.eu/
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
We are a small company with a huge network of specialists
Latest projects:
O-I Glass, bottle manufacturing
- heat recovery for ORC power generation
Yallourn W power station, Australia
1.5GWe, Lignite / brown-coal fired
- condensing heat recovery
- absorbtion chiller
- biomass co-firing
PanPac forest products, New Zealand
Saw mill and pulp production for Oiji paper
- boiler optimization
- pelletizing
- sludge drying
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
E3Agro Best Practice Guide
Ministry of Energy, DEDE, Thailand
&
GTZ, Germany
2004-2008
Key findings:


Typical POM in Thailand 45t FFB/h
Processing steam demand >0.5t steam/t FFB
Energy potentials per POM:

Optimizing existing equipment ~0.5-1.0MWe
HP boiler and using EFB, trunks, fronds >10MWe

Biogas from POME ~1MWe

©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Project data : steam balance today
POM last 12 months:
39 t FFB / h
Balance LP
170,000 t FFB / y
4377 h / y
Feed water
Deaerator
Kernel dryer
Sterilizer
Hot water
Digester
Clearifier
Tanks
CPO tank
Oil recovery
Sludge tank
Losses
demand LP
input LP
Output HP
average steam usage
t/h
3.03
0.50
1.00
8.87
1.01
1.75
0.53
0.22
0.60
0.39
0.30
0.35
18.55
18.54
16.3%
2.7%
5.4%
47.8%
5.4%
9.4%
2.9%
1.2%
3.2%
2.1%
1.6%
1.9%
100.02%
8.9 t / h
Sterilizer
Hot water
Kernel
dryer
1.0 t / h
CPO
processing
4.1 t / h
19.52
1.0 t / h
Fuel available (used):
fiber 25,400 t / y (all)
3.5 t / h
EFB 32,200 t / y (none)
shell 10,100 t / y (1,700)
= - 3,400,000 TBH / y
1.0 t / h
Boiler
5.8 t / h
Fibre
(shell)
BFW
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
 19.5 t / h
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Steam balance optimized
Fuel available @ 200,000 t / y (used):
fiber 30,000 t / y (~ 65%)
average steam usage
optimized / today
7.5 t / h
8.9 t / h
Sterilizer
EFB 38,000 t / y (none)
shell 12,000 t / y (none)
Hot water
= 3,400,000 TBH / y
Kernel
dryer
CPO
processing
Optimizing
el. equipment
0.2 t / h
1.0 t / h
1.0 t / h
1.0 t / h
2.8 t / h
0.6 t / h
Excess steam available
for condensing LP turbine
0.4 t / h
4.1 t / h
1.0 t / h
3.5 t / h
Boiler
3.7 t / h
Fibre
BFW
 12.5 t / h  19.5 t / h
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Value added from Wastewater
1st POM biogas plant in Thailand, won ASEAN price and recognition of Royal family
© STE International Co. , Ltd. Thailand
POM
Since 2002
Process
POME
DTC
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Biogas production POM
KPI 2 ~20kg / t FFB
New developments in supplement and bio-catalyst can increase biogas
production by 50% and stabilize the gas output.
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Biogas CHP heat usage for BFW and LP steam
The heat of the biogas engine cooling can
be used to preheat boiler feed water.
Saving: 1.0 t LP boiler steam / h
Exhaust gas can be utilized to generate
LP steam for FFB processing.
Saving: 1.5 t LP boiler steam / h
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Thailand experience and Indonesia preliminary analysis
Thailand
Indonesia
Introduced Feed In Tariff FIT
Will introduced FIT @ Rp975 x f (1-1.2)
EGAT was very obstructive at first
but learned to appreciate the benefits:
- reduced line losses
- stabilized grid and power factor
- more sales, no investment
PLN is not seeing the advantage yet
Food processing industry grid connected
Good uptake in BM power generation
Lessons learned:
- EFB problematic boiler fuel
- Fuel buying does NOT work
Food industry grid distance depending
on region.
Slow uptake in BM power generation
Government wants 10.000MWe new
generation
Agri-industry has the potential & the fuel
250POM @ 4MWe = 1.000MWe = 10%
Germany has the technology
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Lets talk Rupiah
Agro industry depended on
one price.
CPO CIF Rotterdam
1400
1200
Converting residues to
products:
1000
800
600
Power generation FIT @
Rp975 x f (1-1.2) is very
attractive.
400
200
0
Mar 2010
Jul 2010
Nov 2010
Mar 2011
Jul 2011
Jan 2010
May 2010
Sep 2010
Jan 2011
May 2011
If grid connection is not possible, conversion into products is an option.
The goal is to increase density and moisture content to reduce transport costs
and the value per ton shipped. There are different options:
- compost
- pellets as fuel / fertilizer / animal feed
- 2nd generation bio-fuel / Diesel
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Solid state fermentation to biogas from organic waste like food & greens
Gas storage
Fermenter
Gas cleaning
and de-sulfur
Products:
Biogas +
Compost
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Introduction into Sludge Treatment Technology
Sludges are solids suspended
in waste water from
production, processing or
sewage systems.
Dewatering 1m3 ~ 1000kg
Water [kg]
DS[kg]
1200
1000
800
Due to discharge and disposal
restrictions sludges have to be
treated. They are regarded as
cost factors.
Thickening
600
400
200
Pressing
1.00%
Thin sludge :
0.1%-1%DS
Thickend sludge :
3%-5%DS
Pressed sludge : 26%-36%DS
Dried sludge :
95%-98%DS
DS = dry solids, % = mass%
Drying
0
4.00%
32.00%
96.00%
~ 99% water
~ 95% water
~ 70% water
~ 5% water
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Rapid Sedimentation Technology
Settling and oxidation ponds are
widely used in to thicken sludges.
Problems:
O&M cost, odor, disposal costs
Sand
Catch
Pre-sedimentation
Biology
P&N
Elimination
Post-sedimentation
Scraper
Sludge
Thickening
RAPID SEDIMENTATION TANKS
Fermentation
tower
Bio Reactor
Sludge
Dewatering
Scraper
Sludge
Dewatering
Intermediary tanks
Further Sludge
usage
Only a small area is required
Fast sedimentation technology
delivers superior results at lower
costs.
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Wastewater/Sludge Separation
Sludge Treatment
1 Wastewater
Pelletizing System
3
FP
4
2
Flow chart of the
multi-step process
for pelletizing
sludge.
19
5
18
6
23
8
7
9
20
17
Pellets
10
12
22
21
11
Clean Air
Exhaust
29
28
13
Hot Exhaust Air Supply
Discharged
14
Recycled/
Reuse
Further Purification
25
Fresh Air Intake
15
30
16
26
27
24
Bio Filter
Air Washer
Pellets as fuel
1) Analysis of sludge treatment and recycling options
2) Components (de-watering, pelletizing, drying)
3) Complete sludge treatment systems
4) Integration into existing plant
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Wastewater
Flocculants
RST
A
B
Sludge with 3-5% DS
Pre-Dewatering
A
Pre-Thickening
10-12% DS
Mixer
42-50% DS
Pelletizer
42-50% DS
Drying (Pellets)
95-98% DS
22-24% DS
WMS-Bio
Reactor
Direct discharge
Purified water
Pressing
Recycling and
Re-use
Rapid
Bio Reactor
Sedimentation
Tank
26-28% DS
B
Pre Dewatering
& Thickening
Belt press
Pelletizer
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
Dryer
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Applications of Sludge Treatment Technology
Sludges are thickened in a multi-step process and turned into
a pelletized product. Depending on sludge content and
composition the pellets can be used as:
- Fuel
(steelworks, pulp&paper, sewage)
- Feedstock
(food growing)
- Raw material
(minerals, metal, coal)
And turned into products like:
- Packing material
- Bricks
- Animal feed
- Fertilizer
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Crude oil usage
1Mio car p.m.
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
CDP
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Biomass Chemistry
Production of Synthetic
Diesel from Waste and
Biomass using Catalytic
Depolymerization
Processes (CDP) is
converting Biomass
directly into usable Diesel
Fuel.
Products
CDP example with sewage sludge
Catalyst & heat
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Bio-Diesel is NOT CDP Diesel
Bio-Diesel is a methyl ester with an O bridge and has therefore very different
fuel characteristics to Diesel.



the lubrication properties are different
it is highly corrosive to some alloys and rubbers used in IC engines
it is bio-degradable which causes problems in storage
Bio-Diesel is made from fats and oils used for food. Therefore it is competing
with the human food chain.
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Diesel
physical
properties
Wear, important
since Sulfur
content was
reduced
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Diesel combustion
properties
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Prof.Willner
Prof.Stadlbauer
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Hospital plastic waste, Germany
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Now, that we have completed our work, proven our innovative Technology
through the long term operation of a commercial Pilot plant we do supply
our turn – key production plants to users all over the world with our
unbeatable offer, which is called
“seeing your own plant operating is the ultimate believe”
If a client does order a turn-key conversion plant, we do not ask for payment
right away.
We request the payment only once the plant is fully operational and an
independent surveyor has certified that our contracted deliverables are fact
and not just promises!
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
45t/h POM
using EFB
Production:
1000l/h Diesel
Production cost:
~Rp3.500/l
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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ANNIES Export NZ Ltd
Australian New Zealand New Innovative Energy Solutions
Happy to discuss details
Have a productive day
©2011 ANNIES Export NZ Ltd , annies_export@xtra.co.nz
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