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Fermentation Processing solutions for wet fermentation
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The task at hand Fermentation is the most economically and ecologically viable treatment method for a range of organic waste. Clean energy is produced from the decomposed organic material and compost and liquid fertiliser from the residual fermentation. But packaging, contaminants and inert waste prevent direct introduction into the fermentation process. A smooth, fermentable substrate can not be extracted until the feedstock is subjected to selective stages of treatment. For operators of waste management fermentation plants, it is beneficial to be able to use the broadest spectrum of organic waste input material as possible. A broad scope of waste acquisition, in conjunction with increased efficiency and the option of generating energy-rich substrates with a high gas yield, increases the cost-effectiveness of the plant.
Food residues
By using the right technologies, heavily contaminated market waste and out-of-date food with various levels of packaging can be recycled alongside bio-waste and food residues. Following successful treatment of the waste, the substrate is used in a wet fermentation process. In enclosed reactors, biogas is produced which can be used as an energy source (depending on site specifications). Usage ranges from electrification in cogeneration power plants and thermal applications to purification with subsequent feed into the natural gas grid.
Spoiled food
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Expertise Within the fermentation sector, Komptech is focusing on the complex stages of treatment. The input dictates whether the pulper or pressing processes are used. Pulper process When fermenting using the pulper process, treatment stages extract a fermentation substrate from waste having a high organic content. This is then added to the wet fermentation process. The process may be used for input material having a high contaminant or packaging content as well as for household and residual waste. Pressing process The pressing process is the perfect solution for wet bio-waste. Following selective removal of contaminants, a separation stage in the press process separates the material into a liquid fraction for wet fermentation and a solid fraction for composting.
Wet bio-waste
Komptech GmbH Komptech is a leading international technology supplier of machinery and systems for the mechanical and biological treatment of solid waste and for the treatment of biomass as a renewable energy source. Komptech’s product portfolio includes more than 30 different machine types, enabling the company to be active in the fields of competence treatment of solid waste and treatment of biomass. Komptech products cover the major processing steps of modern waste treatment and biomass processing, namely shredding technology, screening and separation technology and composting technology. Modular construction offering different performance categories simplifies combinations for complete systems. Always the focus: innovative technology and solutions that provide a maximum of benefit for the customers.
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Processing solutions for wet fermentation
Treatment of gas
Liquid Input
Shredding
Pulper Wet-Screen+Press
Sand Separation
Hygienisation
Solid Contaminants
Composting
Dewatering
Fermentation residue liquid: option Agriculture
Pulper process Treatment Packaged, non-homogenous or lumpy waste necessitates pre-shredding. Slow-running shredders which break down the material thoroughly are used. The next stages are the dissolution of the organic materials in the pulper and the subsequent separation of the contaminants. All contaminants such as plastics, metal, glass and sand are separated off from the fermentation substrate. An inert fraction or compostable material may also be present (depending on the input material).
Fermentation The fermentation substrate produced exhibits ideal properties for simple fermentation. The introduction of additional liquid waste is possible. It may be necessary to handle this in one section of the plant - depending on the quality of the waste. The ideal reactor system is based upon the on-site conditions, the waste processed and the statutory requirements under which the site in question is licensed.
Fermentation
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Key components
Shredding Shredding with the dual-shaft shredder CRAMBO provides the optimum size for the largest fraction and reliable opening of packaging and containers. Solution The key component of the treatment stage is the transfer of the organics into the liquid phase. The pulper used performs several tasks. In batch operation, the organics are shredded further and homogenised in the process water. Packaging is emptied
and cleansed by the high flow speed. At the same time, heavy material is separated off through a sluice. Separation and pressing Raw substrate exits the pulper (also as part of the cycle) onto a MULTISTAR star screen, connected downstream. The liquid with the solubilised and suspended organic material flows through the star screen and is collected in a tray from where it is pumped, via sand separation, into the collection tank. Oversized particles (depending
on source material, contaminants or organic residual fraction) are discharged via the star screens and water is removed in a press connected to the main apparatus. Sand separation Technical processes in the subsequent sand separation stage separate off undesirable materials from the fermentation substrate. Sand, stones, glass and ceramics are separated off depending on the source material.
- universal use - for packaged, contrary-rich materials - automatic contrary discharge - fully automated - economical for system input >15,000 tons per year
Material flows Pulper Process
Fermentation
Contaminants Heavy Fraction
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Processing solutions for wet fermentation
Treatment of gas
Liquid Input
Shredding
Star Screen
Press
Sand Separation Hygienisation Fermentation Solid
Contaminants
Composting
Dewatering
Fermentation residue liquid: option Agriculture
Pressing process Treatment Besides green waste, wet bio-waste from municipal collections also contains kitchen and food residue fractions which complicate composting. Separating off these wet fractions produces a dry fraction, rich in structure, for simple composting and an energy-rich fermentation substrate. The separation process necessary for this comprises of pre-shredding, mixing and subsequent pressing of the liquid fractions. An intermediate screening stage ejects contaminants. This technology simplifies the composting of problematic waste and makes the addition of fermentation to the composting process economically viable.
Fermentation The fermentation substrate provides balanced chemical/ physical properties for perfect fermentation. This way it is possible to add mono-substrates such as fats, oils and other problematic liquids without detrimentally affecting biogas production.
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Key components
Shredding A dual-shaft CRAMBO shredder is used for shredding. The organic fraction is digested and plastic bags and other packaging materials are opened up.
significantly improves compost quality. The process can be tailored perfectly to the material supplied using the variable screen section of the MULTISTAR star screen.
Screening In the next stage, impurities in the biowaste, along with woody overlengths and coarse contaminants, are separated off by screening. Taking this step ensures subsequent power assemblies are protected and also
Pressing The MASHSEPARATOR is at the heart of the pressing process. After homogenisation in the mixing vessel, the material is compressed in a spiral press. The liquid squeezed out flows through screen baskets leaving
behind a dewatered press cake for composting. The amount of liquid squeezed out is tailored to the material and subsequent usage. Sand separation As with the pulper process, undesirable contaminants such as sand, stones, glass and ceramics are separated off from the fermentation substrate using sand separation.
- for wet bio-waste - compact treatment and fermentation quantity - optimal combination of fermentation and composting - economical for system input >12,000 tons per year
Material flows Pressing Process
Composting
Fermentation Contaminants
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Verg채rung Technology for a better environment
Komptech GmbH K체hau 37 A-8130 Frohnleiten [t] +43 3126 505 - 0 [f] +43 3126 505 - 505 [e] info@komptech.com
Komptech UK Ltd. Forge End, Lodge Farm, Kineton, Warwickshire, CV35 0JH [t] +44 1926 64 29 72 [f] +44 1926 64 29 71 [e] info.uk@komptech.com
www.komptech.com
Technical information is subject to change due to continued development.
E-10-2009