Tag Archives: Waste-to-energy

Pelletization of Municipal Solid Wastes

  By Salman Zafar | June 5, 2013 - 2:34 pm | Solid Waste Management, Waste-to-energy
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MSW is a poor-quality fuel and its pre-processing is necessary to prepare fuel pellets to improve its consistency, storage and handling characteristics, combustion behaviour and calorific value. Technological improvements are taking place in the realms of advanced source separation, resource recovery and production/utilisation of recovered fuel in both existing and new plants for this purpose. There has been an increase in global interest in the preparation of RDF containing a blend of pre-processed MSW with coal suitable for combustion in pulverised coal and fluidised bed boilers.

Pelletization of municipal solid waste involves the processes of segregating, crushing, mixing high and low heat value organic waste material and solidifying it to produce fuel pellets or briquettes, also referred to as Refuse Derived Fuel (RDF). The process is essentially a method that condenses the waste or changes its physical form and enriches its organic content through removal of inorganic materials and moisture. The calorific value of RDF pellets can be around 4000 kcal/ kg depending upon the percentage of organic matter in the waste, additives and binder materials used in the process.

The calorific value of raw MSW is around 1000 kcal/kg while that of fuel pellets is 4000 kcal/kg. On an average, about 15–20 tons of fuel pellets can be produced after treatment of 100 tons of raw garbage. Since pelletization enriches the organic content of the waste through removal of inorganic materials and moisture, it can be very effective method for preparing an enriched fuel feed for other thermochemical processes like pyrolysis/ gasification, apart from incineration. Pellets can be used for heating plant boilers and for the generation of electricity. They can also act as a good substitute for coal and wood for domestic and industrial purposes. The important applications of RDF are found in the following spheres:

  • Cement kilns
  • RDF power plants
  • Coal-fired power plants
  • Industrial steam/heat boilers
  • Pellet stoves

The conversion of solid waste into briquettes provides an alternative means for environmentally safe disposal of garbage which is currently disposed off in non-sanitary landfills. In addition, the pelletization technology provides yet another source of renewable energy, similar to that of biomass, wind, solar and geothermal energy. The emission characteristics of RDF are superior compared to that of coal with fewer emissions of pollutants like NOx, SOx, CO and CO2.

RDF production line consists of several unit operations in series in order to separate unwanted components and condition the combustible matter to obtain the required characteristics. The main unit operations are screening, shredding, size reduction, classification, separation either metal, glass or wet organic materials, drying and densification. These unit operations can be arranged in different sequences depending on raw MSW composition and the required RDF quality.

Various qualities of fuel pellets can be produced, depending on the needs of the user or market. A high quality of RDF would possess a higher value for the heating value, and lower values for moisture and ash contents. The quality of RDF is sufficient to warrant its consideration as a preferred type of fuel when solid waste is being considered for co-firing with coal or for firing alone in a boiler designed originally for firing coal.

Energy Value of Agricultural Wastes

  By Salman Zafar | May 23, 2013 - 10:41 am | Agricultural Residues, Biomass Energy
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Large quantities of agricultural wastes resulting from crop cultivation activity are a promising source of energy supply for production, processing and domestic activities in rural areas of the concerned region. The available crop residues are either being used inefficiently or burnt in the open to clear the fields for subsequent crop cultivation. On an average 1.5 tons of crop residue are generated for processing 1 ton of the main product. In addition, substantial quantities of secondary residues are produced in agro-industries processing farm produce such as paddy, sugarcane, coconut, fruits and vegetables.

Agricultural crop residues often have a disposal cost associated with them. Therefore, the “waste-to-energy” conversion processes for heat and power generation, and even in some cases for transport fuel production, can have good economic and market potential. They have value particularly in rural community applications, and are used widely in countries such as Sweden, Denmark, Netherlands, USA, Canada, Austria and Finland.

The energy density and physical properties of agricultural biomass wastes are critical factors for feedstock considerations and need to be understood in order to match a feedstock and processing technology. There are six generic biomass processing technologies based on direct combustion (for power), anaerobic digestion (for methane-rich gas), fermentation (of sugars for alcohols), oil exaction (for biodiesel), pyrolysis (for biochar, gas and oils) and gasification (for carbon monoxide and hydrogen-rich syngas). These technologies can then be followed by an array of secondary treatments (stabilization, dewatering, upgrading, refining) depending on specific final products.

It is well-known that power plants based on baled agricultural residues are efficient and cost-effective energy generators. Residues such as Rice Husks, Wheat Straw and Maize Cobs are already concentrated at a point where it is an easily exploitable source of energy, particularly if it can be utilized on-site to provide heat and power.

The selection of processing technologies needs to be aligned to the nature and structure of the biomass feedstock and the desired project outputs. It can be seen that direct combustion or gasification of biomass are appropriate when heat and power are required. Anaerobic digestion, fermentation and oil extraction are suitable when specific Biomass wastes are available that have easily extractable oils and sugars or high water contents. On the other hand, only thermal processing of biomass by pyrolysis can provide the platform for all of the above forms of product. Many thermal technologies require the water content of Biomass to be low (<15 per cent) for proper operation. For these technologies the energy cost of drying can represent a significant reduction in process efficiency.

Moisture content is of important interest since it corresponds to one of the main criteria for the selection of energy conversion process technology. Thermal conversion technology requires biomass fuels with low moisture content, while those with high moisture content are more appropriate for biological-based process such as fermentation or anaerobic digestion.

The ash content of biomass influences the expenses related to handling and processing to be included in the overall conversion cost. On the other hand, the chemical composition of ash is a determinant parameter in the consideration of a thermal conversion unit, since it gives rise to problems of slagging, fouling, sintering and corrosion.

Anaerobic Digestion of Animal Manure

  By Salman Zafar | May 6, 2013 - 10:21 am | Anaerobic Digestion, Biogas
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Cow manure is a valuable source of nutrients and renewable energy. However, most of the manure is collected in lagoons or left to decompose in the open which pose a significant environmental hazard. The air pollutants emitted from manure include methane, nitrous oxide, ammonia, hydrogen sulfide, volatile organic compounds and particulate matter, which can cause serious environmental concerns and health problems. In the past, livestock waste was recovered and sold as a fertilizer or simply spread onto agricultural land. The introduction of tighter environmental controls on odour and water pollution means that some form of waste management is necessary, which provides further incentives for biomass-to-energy conversion.

Anaerobic digestion is a unique treatment solution for animal wastes as it can  deliver  positive  benefits  related  to  multiple  issues,  including  renewable  energy,  water pollution, and air emissions. Anaerobic digestion of animal manure is gaining popularity as a means to protect the environment and to recycle materials efficiently into the farming systems. Waste-to-Energy (WTE) plants, based on anaerobic digestion of cow manure, are highly efficient in harnessing the untapped renewable energy potential of organic waste by converting the biodegradable fraction of the waste into high calorific gases.

The establishment of anaerobic digestion systems for livestock manure stabilization and energy production has accelerated substantially in the past several years. There are thousands of digesters operating at commercial livestock facilities in Europe, United States,  Asia and elsewhere. which are generating clean energy and fuel. Many of the projects that generate electricity also capture waste heat for various in-house requirements.

Important Factors

The main factors that influence biogas production from livestock manure are pH and temperature of the feedstock. It is well established that a biogas plant works optimally at neutral pH level and mesophilic temperature of around 35o C. Carbon-nitrogen ratio of the feed material is also an important factor and should be in the range of 20:1 to 30:1. Animal manure has a carbon – nitrogen ratio of 25:1 and is considered ideal for maximum gas production. Solid concentration in the feed material is also crucial to ensure sufficient gas production, as well as easy mixing and handling. Hydraulic retention time (HRT) is the most important factor in determining the volume of the digester which in turn determines the cost of the plant; the larger the retention period, higher the construction cost.

Process Description

The fresh animal manure is stored in a collection tank before its processing to the homogenization tank which is equipped with a mixer to facilitate homogenization of the waste stream. The uniformly mixed waste is passed through a macerator to obtain uniform particle size of 5-10 mm and pumped into suitable-capacity anaerobic digesters where stabilization of organic waste takes place.

In anaerobic digestion, organic material is converted to biogas by a series of bacteria groups into methane and carbon dioxide. The majority of commercially operating digesters are plug flow and complete-mix reactors operating at mesophilic temperatures. The type of digester used varies with the consistency and solids content of the feedstock, with capital investment factors and with the primary purpose of digestion.

Biogas contain significant amount of hydrogen sulfide (H2S) gas which needs to be stripped off due to its highly corrosive nature. The removal of H2S takes place in a biological desulphurization unit in which a limited quantity of air is added to biogas in the presence of specialized aerobic bacteria which oxidizes H2S into elemental sulfur. Biogas can be used as domestic cooking, industrial heating, combined heat and power (CHP) generation as well as a vehicle fuel. The digested substrate is passed through screw presses for dewatering and then subjected to solar drying and conditioning to give high-quality organic fertilizer.

MSW to Energy at a Glance

  By Salman Zafar | April 24, 2013 - 8:42 am | Solid Waste Management, Waste-to-energy
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MSW-to-Energy is the use of thermochemical and biochemical technologies to recover energy, usually in the form of electricity and steam, from urban wastes. These new technologies can reduce the volume of the original waste by 90%, depending upon composition and use of outputs. The main categories of MSW-to-energy technologies are physical technologies, which process waste to make it more useful as fuel; thermal technologies, which can yield heat, fuel oil, or syngas from both organic and inorganic wastes; and biological technologies, in which bacterial fermentation is used to digest organic wastes to yield fuel.

Components of MSW-to-Energy Systems

  1. Front-end MSW preprocessing
  2. Conversion unit (reactor or anaerobic digester)
  3. Gas cleanup and residue treatment plant
  4. Energy recovery plant (optional)
  5. Emissions clean up

Incineration

  • Combustion of raw MSW, moisture less than 50%
  • Sufficient amount of oxygen is required to fully oxidize the fuel
  • Combustion temperatures are in excess of 850oC
  • Waste is converted into CO2 and water concern about toxics (dioxin, furans)
  • Any non-combustible materials (inorganic such as metals, glass) remain as a solid, known as bottom ash (used as feedstock in cement and brick manufacturing)
  • Fly ash APC (air pollution control residue) particulates, etc
  • Needs high calorific value waste to keep combustion process going, otherwise requires high energy for maintaining high temperatures

Anaerobic Digestion

  •  Well-known biochemical technology for organic fraction of MSW and domestic sewage.
  • Biological conversion of biodegradable organic materials in the absence of oxygen at mesophilic or thermophilic temperatures.
  • Residue is stabilized organic matter that can be used as soil amendment
  • Digestion is used primarily to reduce quantity of sludge for disposal / reuse
  • Methane gas is generated which is used for heat and power generation.

Gasification

  • Can be seen as between pyrolysis and combustion (incineration) as it involves partial oxidation.
  • Exothermic process (some heat is required to initialize and sustain the gasification process).
  • Oxygen is added but at low amounts not sufficient for full oxidation and full combustion.
  • Temperatures are above 650oC
  • Main product is syngas, typically has net calorific value of 4 to 10 MJ/Nm3
  • Other product is solid residue of non-combustible materials (ash) which contains low level of carbon

Pyrolysis

  • Thermal degradation of organic materials through use of indirect, external source of heat
  • Temperatures between 300 to 850oC are maintained for several seconds in the absence of oxygen.
  • Product is char, oil and syngas composed primarily of O2, CO, CO2, CH4 and complex hydrocarbons.
  • Syngas can be utilized for energy production or proportions can be condensed to produce oils and waxes
  • Syngas typically has net calorific value (NCV) of 10 to 20 MJ/Nm

Plasma Gasification

  • Use of electricity passed through graphite or carbon electrodes, with steam and/or oxygen / air injection to produce electrically conducting gas (plasma)
  • Temperatures are above 3000oC
  • Organic materials are converted to syngas composed of H2, CO
  • Inorganic materials are converted to solid slag
  • Syngas can be utilized for energy production or proportions can be condensed to produce oils and waxes
  •  

MSW-to-energy technologies can address a host of environmental issues, such as land use and pollution from landfills, and increasing reliance on fossil fuels. In many countries, the availability of landfill capacity has been steadily decreasing due to regulatory, planning and environmental permitting constraints. As a result, new approaches to waste management are rapidly being written into public and institutional policies at local, regional and national levels.

A Primer on Waste-to-Energy

  By Salman Zafar | March 25, 2013 - 5:07 am | Solid Waste Management, Waste-to-energy
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Energy is the driving force for development in all countries of the world. The increasing clamor for energy and satisfying it with a combination of conventional and renewable resources is a big challenge. Accompanying energy problems in different parts of the world, another problem that is assuming critical proportions is that of urban waste accumulation. The quantity of waste produced all over the world amounted to more than 12 billion tonnes in 2006, with estimates of up to 13 billion tonnes in 2011. The rapid increase in population coupled with changing lifestyle and consumption patterns is expected to result in an exponential increase in waste generation of upto 18 billion tonnes by year 2020.

Waste generation rates are affected by socio-economic development, degree of industrialization, and climate. Generally, the greater the economic prosperity and the higher percentage of urban population, the greater the amount of solid waste produced. Reduction in the volume and mass of solid waste is a crucial issue especially in the light of limited availability of final disposal sites in many parts of the world. Millions of tonnes of waste are generated each year with the vast majority disposed of in open fields or burnt wantonly.

Waste-to-Energy (WTE) is the use of modern combustion and biochemical technologies to recover energy, usually in the form of electricity and steam, from urban wastes. These new technologies can reduce the volume of the original waste by 90%, depending upon composition and use of outputs. The main categories of waste-to-energy technologies are physical technologies, which process waste to make it more useful as fuel; thermal technologies, which can yield heat, fuel oil, or syngas from both organic and inorganic wastes; and biological technologies, in which bacterial fermentation is used to digest organic wastes to yield fuel.

The three principal methods of thermochemical conversion corresponding to each of these energy carriers are combustion in excess air, gasification in reduced air, and pyrolysis in the absence of air. The most common technique for producing both heat and electrical energy from wastes is direct combustion. Combined heat and power (CHP) or cogeneration systems, ranging from small-scale technology to large grid-connected facilities, provide significantly higher efficiencies than systems that only generate electricity. 

Biochemical processes, like anaerobic digestion, can also produce clean energy in the form of biogas which can be converted to power and heat using a gas engine. In addition, wastes can also yield liquid fuels, such as cellulosic ethanol, which can be used to replace petroleum-based fuels. Cellulosic ethanol can be produced from grasses, wood chips and agricultural residues by biochemical route using heat, pressure, chemicals and enzymes to unlock the sugars in biomass wastes. 

Waste-to-energy plants offer two important benefits of environmentally safe waste management and disposal, as well as the generation of clean electric power.  The growing use of waste-to-energy as a method to dispose of solid and liquid wastes and generate power has greatly reduced environmental impacts of municipal solid waste management, including emissions of greenhouse gases. 

Waste Management Outlook for India

  By Ranjith Annepu | March 13, 2013 - 9:03 am | India, Solid Waste Management
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Waste management crisis in India should be approached holistically; while planning for long term solutions, focus on addressing the immediate problems should be maintained. National and local governments should work with their partners to promote source separation, achieve higher percentages of recycling and produce high quality compost from organics. While this is being achieved and recycling is increased, provisions should be made to handle the non-recyclable wastes that are being generated and will continue to be generated in the future.

Recycling, composting and waste-to-energy are all integral parts of the waste disposal solution and they are complementary to each other; none of them can solve India’s waste crisis alone. Any technology should be considered as a means to address public priorities, but not as an end goal in itself. Finally, discussion on waste management should consider what technology can be used, to what extent in solving the bigger problem and within what timeframe.

Experts believe India will have more than nine waste-to-energy projects in different cities across India in the next three years, which will help alleviate the situation to a great extent. However, since waste-to-energy projects are designed to replace landfills, they also tend to displace informal settlements on the landfills. Here, governments should welcome discussions with local communities and harbor the informal recycling community by integrating it into the overall waste management system to make sure they do not lose their rights for the rest of the city’s residents.

This is important from a utilitarian perspective too, because in case of emergency situations like those in Bengaluru, Kerala, and elsewhere, the informal recycling community might be the only existing tool to mitigate damage due to improper waste management as opposed to infrastructure projects which take more than one year for completion and public awareness programs which take decades to show significant results.

Involvement of informal recycling community is vital for the success of any SWM program in India

Indian policy makers and municipal officials should utilize this opportunity, created by improper waste management examples across India, to make adjustments to the existing MSW Rules 2000, and design a concrete national policy based on public needs and backed by science. If this chance passes without a strong national framework to improve waste management, the conditions in today’s Bengaluru, Thiruvananthapuram, Kolkata, Mumbai, Chennai, Coimbatore and Srinagar will arise in many more cities as various forcing factors converge. This is what will lead to a solid waste management crisis affecting large populations of urban Indians.

The Indian Judiciary proved to be the most effective platform for the public to influence government action. The majority of local and national government activity towards improving municipal solid waste management is the result of direct public action, funneled through High Courts in each state, and the Supreme Court. In a recent case (Nov 2012), a slew of PILs led the High Court of Karnataka to threaten to supersede its state capital Bengaluru’s elected municipal council, and its dissolution, if it hinders efforts to improve waste management in the city. In another case in the state of Haryana, two senior officials in its urban development board faced prosecution in its High Court for dumping waste illegally near suburbs. India’s strong and independent judiciary is expected to play an increasing role in waste management in the future, but it cannot bring about the required change without the aid of a comprehensive national policy.

Note: Acknowledgements will be published in the full report “Observations from India’s Crisis” on wtert.org and blog.wtert.org

Municipal Solid Wastes in Bahrain

  By Salman Zafar | February 27, 2013 - 4:47 pm | Middle East, Solid Waste Management
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The Kingdom of Bahrain is an archipelago of around 33 islands, the largest being the Bahrain Island. The population of Bahrain is around 1.2 million marked by population density of 900 persons per km2, which is the highest in the entire GCC region. The country has the distinction of being one of the highest per capita waste generators worldwide which is estimated at 1.67 – 1.80 kg per person per day. Infact, Bahrain produces largest amount of waste per person among GCC countries despite being the smallest nation in the region. Rising population, high waste generation growth rate, limited land availability and scarcity of waste disposal sites has made solid waste management a highly challenging task for Bahrain’s policy-makers, urban planners and municipalities.

Municipal Solid Wastes in Bahrain

Bahrain generates more than 1.2 million tons of solid wastes every year. Daily garbage production across the tiny Gulf nation exceeds 4,500 tons. Municipal solid waste is characterized by high percentage of organic material (around 60 percent) which is mainly composed of food wastes. Presence of high percent of recyclables in the form of paper (13 percent), plastics (7 percent) and glass (4 percent) makes Bahraini MSW a good recycling feedstock, though Informal sectors are currently responsible for collection of collection of recyclables and recycling activities

The Kingdom of Bahrain is divided into five governorates namely Manama, Muharraq, Middle, Southern and Northern. Waste collection and disposal operation in Bahrain is managed by a couple of private contractors. Gulf City Cleaning Company is active in Muharraq and Manama while Sphinx Services is responsible for Southern, Middle, and Northern Areas. The prevalent solid waste management scenario is to collect solid waste and dump it at the municipal landfill site at Askar.

Askar, the only existing landfill/dumpsite in Bahrain, caters to municipal wastes, agricultural wastes and non-hazardous industrial wastes. Spread over an area of more than 700 acres, the landfill is expected to reach its capacity within the next few years. The proximity of Askar landfill to urban habitats has been a cause of major environmental concern. Waste accumulation is increasing at a rapid pace which is bound to have serious impacts on air, soil and groundwater quality in the surrounding areas.

Askar Waste-to-Energy Project

The Askar Waste to Energy Project is a pioneering Public-Private Partnership venture and will be based on Build-Operate-Transfer model. The USD480 million waste incineration facility will treat 390,000 tons of solid wastes per year thereby generating 25MW of power which will be fed into the national grid. The project is expected to increase the life span of Askar landfill which is filling up rapidly and would reach its capacity by 2016. The project, expected to commence operations in 2013, will also ease solid waste management situation in the capital city Manama and provide an alternative means for power production in the country.

Conclusions

The Kingdom of Bahrain is grappling with waste management problems arising out of high population growth rate, rapid industrialization, high per capita waste generation, unorganized SWM sector, limited land resources and poor public awareness. The government is trying hard to improve waste management scenario by launching recycling initiatives, waste-to-energy project and public awareness campaign. However more efforts, in the form of effective legislations, large-scale investments, modern SWM technology deployment and environmental awareness, are required from all stake holders to implement a sustainable waste management system in Bahrain.

Rationale for Solid Waste Management

  By Ranjith Annepu | December 8, 2012 - 12:38 pm | India, Solid Waste Management
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Some countries have achieved considerable success in solid waste management. But the rest of the world is grappling to deal with its wastes. In these places, improper management of solid waste continues to impact public health of entire communities and cities; pollute local water, air and land resources; contribute to climate change and ocean plastic pollution; hinder climate change adaptation; and accelerate depletion of forests and mines.

Compared to solid waste management, we can consider that the world has achieved significant success in providing other basic necessities like food, drinking water, energy and economic opportunities. Managing solid wastes properly can help improve the above services further. Composting organic waste can help nurture crops and result in a better agricultural yield. Reducing landfilling and building sanitary landfills will reduce ground and surface water pollution which can help provide cleaner drinking water. Energy recovery from non-recyclable wastes can satiate significant portion of a city’s energy requirement.

Inclusive waste management where informal waste recyclers are involved can provide an enormous economic opportunity to the marginalized urban poor. Additionally, a good solid waste management plan with cost recovery mechanisms can free tax payers money for other issues. In the case of India, sustainable solid waste management in 2011 would have provided

  • 9.6 million tons of compost that could have resulted in a better agricultural yield
  • energy equivalent to 58 million barrels of oil from non-recyclable wastes
  • 6.7 million tons of secondary raw materials to industries in the form of recyclable materials and livelihood to the urban poor

Solid waste management until now has only been a social responsibility of the corporate world or one of the services to be provided by the municipality and a non-priority for national governments. However, in Mumbai, the improperly managed wastes generate 22,000 tons of toxic pollutants like particulate matter, carbon monoxide, nitrous and sulfur oxides in addition to 10,000 grams of carcinogenic dioxins and furans every year. These numbers are only for the city of Mumbai. This is the case in cities all across the developing world. There are numerous examples where groundwater is polluted by heavy metals and organic contaminants due to solid waste landfills.

Solid waste management expenditure of above $ 1 billion per year competes with education, poverty, security and other sustainable initiatives in New York City. Fossil fuels for above 500,000 truck trips covering hundreds of miles are required to transport NYC’s waste to landfills outside the city and state. Similarly, New Delhi spends more than half of its entire municipal budget on solid waste management, while it is desperate for investments and maintenance of roads, buildings, and other infrastructure.

Solid waste management is not just a corporate social responsibility or a non-priority service anymore. Improper waste management is a public health and environmental crisis, economic loss, operational inefficiency and political and public awareness failure. Integrated solid waste management can be a nation building exercise for healthier and wealthier communities. Therefore, it needs global attention to arrive at solutions which span across such a wide range of issues.

Note: Acknowledgements will be published in the full report “Observations from India’s Crisis” on wtert.org and blog.wtert.org

Waste to Energy Pathways

  By Salman Zafar | August 11, 2012 - 7:06 pm | Solid Waste Management, Waste-to-energy
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The conversion of waste material to energy can proceed along three main pathways – thermochemical, biochemical and physicochemical.

Thermochemical Conversion

Thermochemical conversion, characterized by higher temperature and conversion rates, is best suited for lower moisture feedstock and is generally less selective for products. Thermochemical conversion systems consist of primary conversion technologies which convert the waste into heat or gaseous and liquid products, together with secondary conversion technologies which convert these products into the more useful forms of energy being heat and electricity. The three principal methods of thermochemical conversion corresponding to each of these energy carriers are combustion in excess air, gasification in reduced air, and pyrolysis in the absence of air.

Gasification of wastes takes place in a restricted supply of oxygen and occurs through initial devolatilization of the biomass, combustion of the volatile material and char, and further reduction to produce a fuel gas rich in carbon monoxide and hydrogen. This combustible gas has a lower calorific value than natural gas but can still be used as fuel for boilers, for engines, and potentially for combustion turbines after cleaning the gas stream of tars and particulates.  Pyrolysis enables wastes to be converted to a combination of solid char, gas and a liquid bio-oil. Using fast pyrolysis, bio-oil yield can be as high as 80 percent of the product on a dry fuel basis. Bio-oil can act as a liquid fuel or as a feedstock for chemical production.

Biochemical Conversion

Biochemical conversion processes, which include anaerobic digestion and fermentation, are preferred for wastes having high percentage of organic biodegradable matter and high moisture content. Anaerobic digestion is a biological treatment method that can be used to recover both nutrients and energy contained in organic wastes such as animal manure. The process generates gases with a high content of methane (55–65 %). Anaerobic digestion also results in a dry residue called digestate which can be used as a soil conditioner.

Alcohol fermentation is the transformation of organic fraction of waste to ethanol by a series of biochemical reactions using specialized microorganisms. Cellulosic ethanol can be produced from grasses, wood chips and agricultural residues by biochemical route using heat, pressure, chemicals and enzymes to unlock the sugars in biomass wastes.

Physico-chemical Conversion

The physico-chemical technology involves various processes to improve physical and chemical properties of solid waste. The combustible fraction of the waste is converted into high-energy fuel pellets which may be used in steam generation. The waste is first dried to bring down the high moisture levels. Sand, grit, and other incombustible matter were then mechanically separated before the waste is compacted and converted into pellets.

Fuel pellets have several distinct advantages over coal and wood because it is cleaner, free from incombustibles, has lower ash and moisture contents, is of uniform size, cost-effective, and eco-friendly.

Anaerobic Digestion of Tannery Wastes

  By Salman Zafar | July 30, 2012 - 5:57 pm | Anaerobic Digestion, Biogas, Industrial Waste Management
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The conventional leather tanning technology is highly polluting as it produces large amounts of organic and chemical pollutants. Wastes generated by the leather processing industries pose a major challenge to the environment. According to conservative estimates, about 600,000 tons per year of solid waste are generated worldwide by leather industry and approximately 40–50% of the hides are lost to shavings and trimmings.

Everyday a huge quantity of solid waste, including trimmings of finished leather, shaving dusts, hair, fleshing, trimming of raw hides and skins, are being produced from the industries. Chromium, sulphur, oils and noxious gas (methane, ammonia, and hydrogen sulphide) are the elements of liquid, gas and solid waste of tannery industries.

Anaerobic digestion (or biomethanation) systems are mature and proven processes that have the potential to convert tannery wastes into energy efficiently, and achieve the goals of pollution prevention/reduction, elimination of uncontrolled methane emissions and odour, recovery of bio-energy potential as biogas, production of stabilized residue for use as low grade fertilizer.

Anaerobic digestion is a favorable technological solution which degrades a substantial part of the organic matter contained in the sludge and tannery solid wastes, generating valuable biogas, contributing to alleviate the environmental problem, giving time to set-up more sustainable treatment and disposal routes. Digested solid waste is biologically stabilized and can be reused in agriculture.

The application of an anaerobic treatment for the break down of COD from tannery waste water is an attractive method to recover energy from tannery wastewater. Until now it was considered that the complexity of the waste water stream originating from tanneries in combination with the presence of chroming would result in the poisoning of the process in a high loaded anaerobic reactor.

When the locally available industrial wastewater treatment plant is not provided by anaerobic digester, a large scale digestion can be planned in regions accommodating a big cluster of tanneries, if there is enough waste to make the facility economically attractive. In this circumstance, an anaerobic co-digestion plant based on sludge and tanneries may be a recommendable option, which reduces the quantity of landfilled waste and recovers its energy potential. It can also incorporate any other domestic, industrial or agricultural wastes. Chrome-free digested tannery sludge also has a definite value as a fertilizer based on its nutrient content.

Biogas produced in anaerobic digesters consists of methane (50%–80%), carbon dioxide (20%–50%), and trace levels of other gases such as hydrogen, carbon monoxide, nitrogen, oxygen, and hydrogen sulfide.  Biogas can be used for producing electricity and heat, as a natural gas substitute and also a transportation fuel. A combined heat and power plant system (CHP) not only generates power but also produces heat for in-house requirements to maintain desired temperature level in the digester during cold season.

CHP systems cover a range of technologies but indicative energy outputs per m3 of biogas are approximately 1.7 kWh electricity and 2.5kWh heat. The combined production of electricity and heat is highly desirable because it displaces non-renewable energy demand elsewhere and therefore reduces the amount of carbon dioxide released into the atmosphere.