In Germany, the various waste products from manufacturing processes that are suitable for mono-fermentation include agricultural residue like manure, energy crops or fodder residue in particular. In contrast, the substantial volumes of waste water produced by the palm oil industry are the most important raw materials in Indonesia or Malaysia, the principal palm oil cultivation regions.
Developed to suit the respective waste products and the local circumstances, ENSPAR builds and delivers efficient process engineering solutions – from individual components with modular structures to one-stop solutions made of high-quality stainless steel.
Below we will use the example of a palm oil mill in Indonesia to outline briefly how a biogas plant can be integrated successfully in an ongoing business.
Waste water from the palm oil industry – which until now has been collected and processed in open lagoons – is transported in the current, open channel to the new biogas plant 1 kilometre away. The lagoons already located there are used to store the sludge from the mill. A digester with a capacity of approx. 6,000 m³ is built for the fermentation process.
Sand and fibrous substances are filtered out of the waste water before it is fed into the biogas plant, and a mechanical process is applied as well to reduce the DM concentration to below 0.5%. The pretreated waste water is cooled in a heat exchanger with cooling tower and then hydrolysed in an initial fermenter. The hydrolysed waste water is then pumped into the second fermenter where the biogas is produced.
Assuming a waste water volume of 19.5 m³/h, a COD degradation rate of approx. 80 % and a yield of around 0.5 m3 biogas/kg COD, the plant will produce approximately 507 m3 biogas/h with an electrical capacity of ~1.240.0kW. The biogas obtained in this way is converted into electricity and heat in a cogeneration unit. This reduces both the waste water volumes and the power costs in the business.
For this scheduled project, ENSPAR is delivering the heat exchangers and fermenter, including the stainless steel hydrolysis system with measurement technology for pH, COD and temperature, as well as the safety technology, the NaOH dispenser, mixers, pumps and controls.
All components will be manufactured and finished in Germany, are easy to transport due to their modular structure and can be shipped worldwide. Our experienced technicians will support on-site assembly, which will take just a few weeks.