Status and Trends of In Vessel Composting Systems in...
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Status and Trends of In Vessel Composting Systems in EuropeKarsten Runge & Thomas Hoelscher, BACKHUS GmbH, Edewecht, Germany
USCC 17th Annual Conference & Trade Show, January 26-29, 2009, Houston, TX
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Content:
1. Composting in Europe
2. Current Status of In Vessel Systems in Europe
3. Trends and Future Developments in Europe
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Statistics
Composting in Europe
Production of compost in the European Union (EU 27, year 2005):
Compost from bio-waste (SSO from private houses): 4.8 Mil t/aCompost from green waste (organics from parks and gardens): 5.7 Mil t/aCompost t/a from biosolids: 1.4 Mil t/aCompost from MSW: 1.4 Mil t/a
Currently collected source separated organic waste in the EU: approx. 24 Mil t/a
Estimated total potential of SSO: 35 to 40 Mil t/a
Market for compost product market share Average price
Agriculture 50 % 0 to 3.00 USD/tLandscaping 20 % 2.00 to 19.00 USD/tGardening & others 30 % 19.00 to 400.00 USD/t
Current number of composting facilities in EU: approx. 3,500
Investment costs per ton anual throughput capacity:open windrow composting: 80.00 to 200.00 USDin vessel composting and fermentation: 475.00 to 675.00 USD
Source: Green Paper on the Management of Bio-Waste in the European Union, published 08-12-03
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Why In Vessel Composting in EU?
Composting in Europe
Traditional reasons for using in vessel composting:
- High level emission control required by neigbourhoods and/or governing agency- Protection of the composting process by elimination of climatic influences- High level process control requested due to sensitive input material
Advantages compared to open air windrow composting:
- Reduced facility foot print (higher throughput on less space)- Lower operating costs (less staff needed due to high degree of process automation)- Increased efficiency (less process time required if process control is working well)- Control any environmental impacts
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Status Quo of In Vessel Composting in Europe
Non agitated in vessel systems:
- Tunnel Composting (enclosed concrete tunnel)- Container Composting (enclosed insulated metal containers)- Box Composting (open top boxes with retractable roof system)- Silo Composting (vertical vessel)
Agitated in vessel systems:
- Agitated Bay Composting (agitated trapeziod windrow in enclosed building)- Agitated Lane Composting (agitated narrow bays typically made of concrete)- Drum or Trommel Composting (rotating horizontal cylindrical vessel)
Available in vessel composting systems
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Status Quo of In Vessel Composting in Europe
Manufacturers (past & present) Herhof, Horstmann, Linde, MUT, RosRoca, Gicom….EU facilities in operation > 100
Advantages (compared with agitated systems):- Batch process in separate tunnels (different batches/feedstocks can be treated seperately)- Small units (lower air volumes required)- No agitation devices (less wear and corrosion)
Disadvantages (compared with agitated systems):- No intervention possible (for corrective action while material is in the tunnel)- Heterogeneous heap (material settles and dry, anaerobic pockets possible)- No visual inspection (no direct access to input material)- Costly and time consuming turning process (with loader or by push floor/conveyor belts)
Tunnel Composting
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Container CompostingManufacturers (past & present) Thoeni, Rethmann, Mannesmann-Lentjes, BioSal...EU facilities in operation > 100
Advantages (compared with agitated systems):- Batch process in separate containers (different batches/feedstocks can be treated seperately)- Small units ( low air volumes required)- No agitation devices (less wear and corrosion)
Disadvantages (compared with agitated systems):- No intervention possible (for corrective action while material is in the tunnel)- Heterogeneous heap (material settles and dry, anaerobic pockets possible)- No visual inspection (no direct access to input material)- Costly and time consuming turning process (with loader)
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Status Quo of In Vessel Composting in Europe
Manufacturers (past & present) Biodegma, Wasteology, Agrivert, CRS ….EU facilities in operation > 50
Advantages (compared with agitated systems):- Batch process in separate vessels (variation and separate treatment of batches possible)- Small volume vessels (lower air volumes required)- No agitation devices (less wear and corrosion)- Lower investment costs (partially non concrete vessel design)
Disadvantages (compared with agitated systems):- No intervention (for corrective action while material is in the tunnel)- Heterogeneous heap (material settles and dry, anaerobic pockets possible)- No visual inspection (no direct access to input material)- Costly and time consuming turning process (with loader or by push floor/conveyor belts)
Box Composting
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Status Quo of In Vessel Composting in Europe
Manufacturers (past & present) VCU, Weiss….EU facilities in operation < 10
Advantages (compared with agitated systems):- Small units (lower air volumes to be treated)- No agitation devices (less wear and corrosion)- Small foot print
Disadvantages (compared with agitated systems):- No intervention possible (for corrective action while material is in the silo)- No visual inspection (no direct access to input material)- Impossible to turn the material
Silo Composting
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Status Quo of In Vessel Composting in Europe
Manufacturers (past & present) Bühler, Kelag VKW, TAIMWeser, Sutco, …EU facilities in operation > 40
Advantages (compared with agitated systems):- Optimized process (constant agitation and irrigation)- Easy control (manual access to the compost material)- Easy material handling (flow through operation)
Disadvantages compared with agitated systems:- Corrosion (agitation system stays in agressive environment)- Large volumes of contaminated air to treat (typically large buildings)- No possibility for separate charge treatment (one vessel, flow trough operation)
Agitated Bay Composting
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Status Quo of In Vessel Composting in Europe
Manufacturers (past & present) Siloda, Sutco, Metrocompost, BACKHUS…EU facilities in operation > 30
Advantages (compared with non agitated systems):- Optimized process (constant agitation and irrigation)- Easy process control (manual access to the compost material)- Easy material handling (flow through operation)- Possibility for treatment variation (several separate vessels)
Disadvantages (compared with non agitated systems):- Corrosion (agitation system stays in agressive environment)- Large volumes of contaminated air to treat (typically large buildings)- Costly civil works / construction
Agitated Lane Composting
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Status Quo of In Vessel Composting in Europe
Manufacturers (past & present) Bedminster, Dano, MUT, Envital, RosRoca…EU facilities in operation approx. 25
Advantages (compared with non agitated systems):- Optimized process (constant agitation and irrigation)- Easy material handling (flow through operation)- Smaller air volumes to be treated
Disadvantages (compared with non agitated systems):- Corrosion (agitation elements stays in agressive environment)- No possibility for separate charge treatment (one vessel, flow trough operation)
Drum composting
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Trends and further development in Europe
What is the ideal In Vessel Composting System?
- Optimized process (constant agitation and irrigation)- Easy material handling (continuous process)- Small air volumes to be treated- Possibility for process variation (several separate vessels)- Handle a variety of input materials- Easily expandable- Proven operating costs- …
What´s next?
- Lower investment costs- Lower operating costs- More flexible system operation- More reliability- Better emission protection- ……
In Vessel Systems – trends and the search of the ideal concept
Looking for all-in-one device suitable for every purpose??
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Trends and further development in Europe
Moving to the ideal concept:
- Evaluation of estabilshed systems by analizing the pro‘s and con‘s- Looking for intelligent combinations of existing technologies and new concepts
What do we need?
• Vessel• Special top roof enclosure• Under floor areation system• Exhaust air system• Agitation system• Irrigation system• Control system
→ developing a new system
In Vessel Systems – New Developments
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Trends and further development in Europe
- Lane style concrete vessel, 14.8‘ wide, 8.2‘ high- Agitation by a newly designed horizontal turning system-Closed vessel featuring unique roof and door design- Fully automatic operation possible
Seeing is believing (testing a new style in vessel system)
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Trends and further development in Europe
- Driver operated lane turner with unique rotor design- Under floor aeration system and exhaust air biofilter- Pilot project operation begin in December 2008
Seeing is believing (testing new style in vessel system)
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Trends and further development in Europe
Lessons learned from pilot test so far:
Closed tunnel environment design now proven
Ventilation and bio-filter properly manage odors and emissions within tunnels
Designing „three zones“ along vessel length with adjustments for moisture addition andventilation optimization:
Drying and Yield lossBiodegradationOr a combination of the two
Although compost was used for the initial prototype - anticipated bio-degradation asumedfrom 65% to 80% depending on time in tunnel and air and moisture applied
- ……
New style in vessel system – pilot test results
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Trends and further development in Europe
Targets for Improvement:
- Improving irrigation systems (three zones)
- Improving monitoring and control systems (automatic optimization of air flow)
- Proving the system for treatment of other input materials
-Next batch testing with sewage sludge to assess ABPR* capability within tunnel- MSW for confirming biodegradation performance in practice-Soil remediation potential
-Assess product output for pelleting or Waste to Energy potential
*ABPR: Animal By Products Regulation
still on the a to the ideal In Vessel Composting S stem
In Vessel Systems – future outlook
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Thank you for your attention!
For further information please contact
Bjoern de Haan, Booth #37Lyndell Pate, Booth #38
www.backhus.uswww.n40compost.com