Piccinini Energy Organic Fertilizer - C.R.P.A · Energy and organic fertilizer from a dairy cattle farm The valorisation of matter: organic fertilizer production After anaerobic digestion

Centro Ricerche Produzioni Animali – C.R.P.A. S.p.A.

International conference

ManuREsource 2013Manure management

and valorization

December 5‐6, 2013 Bruges, Belgium

Energy and organicfertilizer from a dairycattle farmS. Piccinini, L. Rossi, N. Labartino,G. Moscatelli, C. FabbriCRPA – Research Centre on Animal Production - Reggio Emilia - ITALY

Energy and organicfertilizer from a dairy cattle farmThe Dairy cattle farm

Biogas plant

Stable

House

The Agricola Antonio Farm is a dairy cattle farm (productionof drinking milk) in the province of Bologna , Italy.The dairy cows in production are about 200 (400 heads ofcattle in total) and the agricultural area cultivated is 477 ha.

Energy and organicfertilizer from a dairy cattle farmOperational scheme of the farm

Energy and organicfertilizer from a dairy cattle farm

Energetic enhancement: biogas productionFirst plant

State system: Operating since 2009 Manufacturer: B.T.S. Italia Substrates processed: cattle slurry, maize silageProcess temperature: about 40 °C Reactor type: CSTR Digesters volume: 2 x 1900 m3

Covered storage tank volume : 4700 m3

Hydraulic retation time (HRT): 80 days

Engine: Jenbacher mod. JGS 320;Elettric power installated: 1 MWeProduction of electricity: total 8,400 MWh/y

net 8,000 MWh/yDaily biogas production: 10,500 m³/day

( 55% CH4)


First Biogas plant:Organic load in the monitored period

Substrate processed:organic load 8908 t VS (in 16.3 months)

(%VS from each substrates)

Maize silage; 47,04%

Maize silage with onions; 24,84%

Cob maize silage; 0,10%

Mix of silages; 2,11%

Vegetable by-products; 1,13% Cow manure;

24,77%


First Biogas plant: production indices

Results (average values) of monitoring activity

(1) CHP maintenance (2) installation of a biomass extruder

Energy and organicfertilizer from a dairy cattle farmFirst Biogas plant: heat use

The surplus heat is partly used for drying hay (about 5000 t/y) and warm the house of the farmer (about 250 m2).About 1,200 MWhth /y

Forage drying


The new biogas plant: the farmer at the end of 2012, has built another biogas plant, within the same farm

State system: Operating since 2013Manufacturer: B.T.S. Italia Substrates processed: cattle manure,maize silage, straw and stalksProcess temperature: about 40 °C Reactor type: CSTRPre-tank, hydrolysis step: 470 m3

Digester volume: 1 x 3000 m3

Hydraulic retation time (HRT): 70 daysEngine: Jenbacher mod. JGS 320;Elettric power installated: 1 MWeProduction of electricity: net 8,000 MWh/y

The vegetable matrices (maize silage, straw and stalks), beforehydrolysis step, are chopped in an extruder.


The valorisation of matter: organic fertilizer production

After anaerobic digestion aninnovative line of digestatedrying was built, with agrant from the RuralDevelopment Programme ofthe Emilia-Romagna region.

Input dryer: 22.2 t/dayOutput dryer: 2-3 t/day

(85-90%TS)



The system uses theresidual heat ofcogeneration and is ableto also exploit theresidual heat potential ofthe drying air to thicken apart of the liquid fractionof the digestate resultingfrom the solid / liquidseparation.


Layout of the new biogas plant (Anaerobic Digestion + dryer +pelletizer)



Raw digestate Dried digestatepH [-] 7.9 ± 0.1 7.2 ± 0.7

[g/kg] 99.1 ± 8.2 870.6 ± 80.7[%] 9.9 ± 0.8 87 ± 8

[g/kg] 75.8 ± 8.3 701.9 ± 62.6[%TS] 76.4 ± 2.6 80.6 ± 1.4

[mg/kg] 6591 ± 717 18240 ± 2691[%TS] 6.6 ± 0.7 2 ± 0.2

[mg/kg] 3758 ± 393 1976 ± 1293[%TKN] 57 ± 1.8 10.7 ± 7.4[mg/kg] 1376 ± 333 8456 ± 1693[%TS] 1.4 ± 0.3 1 ± 0.1

[mg/kg] 4755 ± 608 28596 ± 24345[%TS] 5.1 ± 0.4 3.2 ± 2.5[%TS] ‐ 41.5 ± 3.1

C/N ‐ 21.2 ± 2.5E.Coli MPN/g (*) ‐ <10

Salmonella P/A in 25 g (**) ‐ Absence

Parameter

P

K

TOC

TS

VS

TKN

NH4+ - N

Measureddata(7 samples)



The air, rich in water vapor, ammonia, and malodorouscompounds, resulting from drying of the digestate, istreated in an acid scrubber with production of anammonium sulfate solution that can be used to increasethe Nitrogen content in the organic fertilizer or can bemarketed as liquid nitrogenous fertilizer.



The dried digestateis then subjected topelletization, withproduction oforganic fertilizerfreely marketableunder the Italianlegislation(Legislative Decreen. 75/2010)

Organic fertilizer production line with Pelletizer ( in the starting phase )


Anaerobic DigestionDigestate drying system

Organicfertilizer

Digestate (65% of total):8092 t/yTS 1010 t/yNTK 64.3 t/y

Dry fraction

Air withammonia

Scrubber Nitrogenliquidfertilizer

Pelletizer

The valorisation of matter: maximum organic fertilizer production

1188 t/yTS 1010 t/yNTK 35.7 t/y

434 t/yNTK 26 t/y

Energy and organicfertilizer from a dairy cattle farmDigestate drying system: nitrogen bilance

Energy and organicfertilizer from a dairy cattle farmConclusions

• The multifunctionality and resilience ofdairy farms also passes through theexploitation of energy and matter(organic fertilizer) of the manure;

• Anaerobic digestion is a reliable andflexible process that enables thisexploitation of the manure.

Centro Ricerche Produzioni Animali – C.R.P.A. S.p.A.

International conference

ManuREsource 2013Manure management

and valorization

December 5‐6, 2013 Bruges, Belgium

[email protected]

Thank for your attention

Documents

Piccinini Energy Organic Fertilizer - C.R.P.A · Energy and organic fertilizer from a dairy cattle farm The valorisation of matter: organic fertilizer production After anaerobic digestion