WO2017121422A1

WO2017121422A1 - Process for material and energy recovery of liquid and finely divided residues from palm oil extraction

Info

Publication number: WO2017121422A1
Application number: PCT/DE2017/000001
Authority: WO
Inventors: Hans-Joachim Auerbach
Original assignee: Apelt, Christine
Priority date: 2016-01-11
Filing date: 2017-01-03
Publication date: 2017-07-20
Also published as: DE102016000198A1

Abstract

The present invention specifies a technical solution by means of which liquid (1) and finely divided residues from palm oil extraction are recovered while avoiding environmental pollution. To this end, proven biotechnological process steps are employed such that the potential of biogenic carbon present in the residues remains largely energetically unlocked and the plant nutrients present in the residues remain preserved in a predominantly plant-available form. To this end, fat fractions and suspended matter are removed from the liquid residues (1) in a first step. While the thus obtained aqueous phase (3) is subjected to anaerobic treatment preferably in a fixed bed fermenter (4) over a period of merely not more than 5 days the anaerobic treatment of the sludge (5) separated from the liquid residues is effected together with other finely divided residues (24, 25, 26, 29) in comparatively small process containers (30, 31, 32) in a multistage procedure over a period of at least 25 days.

Description

Patent Description

title

Process for the material and energetic utilization of liquid and finely divided residues of palm oil production Field of application of the invention

The invention relates to a method for material and energetic

Utilization of liquid and finely divided residues of palm oil production. Such a technical solution is in factories for

Vegetable oil recovery, preferably in palm oil mills needed. State of the art

The extraction of palm oil in many regions of the world has a considerable economic importance for both the fat supply of the

Food industry and other industries as well as the preservation of the cultural landscape. Even in modern so-called palm oil mills, the ratio of recovered palm oil to accumulated biogenic residues is not changed compared to traditional techniques. Relative to a mass fraction FFB (Fresh Fruit Bunches) is associated with the accumulation of commercial products in the form of

0.21 to 0.25 parts by weight of palm oil,

0.023 to 0.027 parts by weight of palm kernel oil,

0.07 to 0.075 parts by weight KS (Kernel Shells) and

0.024 to 0.028 parts by weight KC (Kernel Cake)

and with the accumulation of biogenic residues in the form of

- 0.22 to 0.25 parts by weight of EFB (Empty Fruit Bunches),

0.06 to 0.08 parts by mass DS (Decanter Sludge),

0.8 to 1.1 parts by weight of POME (Palm Oil Mill Effluent),

0, 13 to 0, 16 parts by mass MF (Mesocarp Fibers)

expected. At the expense of ecological problems, most of the accumulating MF is utilized energetically and the resulting EFB is energetically utilized by means of conventional steam boiler technology. Because of the costs incurred with low melting temperatures slags these

Recycling processes regularly disturbed. The plant nutrients nitrogen and sulfur contained in the recycled material are basically lost to the economic cycle and at the same time lead to avoidable emissions

Air pollutants. The resulting potassium and phosphorus-containing

Boiler ash is only occasionally used as nutrient-containing fertilizer. As an alternative to energy recovery by means of combustion processes, according to the state of the art, predominantly only the disordered composting with the consequent consequences for the climate load by emitting noxious gases, such as methane, ammonia and nitrous oxide, and the inevitable loss of nutrients is available for the residues EFB and MF. On the other hand, there are at least partial material and energetic ones

Recycling of residues POME and DS already realized examples in connection with the application of biotechnical aerobic and anaerobic processes. A variety of further developments has been used primarily for energy recovery with simultaneous reductions in the

Air injury.

Thus, it is proposed in WO 00/41976 (1999) to treat the ingredients contained in POME first in aerated lagoons for biomass production as feed for fish farming and then to prepare them in so-called fining ponds to be flooded wastewater. In addition, the use of the energy potential contained in the POME is not

Subject of this proposal.

The US 2010/0197780 Al (2008) describes a technical solution, with the help of the POME ingredients are removed, which could be used for example in cancer treatment. However, the description of the development of the plant nutrients contained in the POME and the use of the contained energetic potential are not to be inferred from the description.

WO 2009/131265 A1 (2008) describes a method proposal which provides for the mixing of EFB, KS, MF, DS and POME and the subsequent treatment with a so-called functional microbial community (FMC), to obtain a biofertilizer with plant growth promoting activity or fungicidal activity. While the required crushing of EFB is known to be a wear and energy-intensive process, the use of the energetic potential of these residues remains unnoticed in this proposal.

With WO 2010/138254 AI (2009), a technical solution proposal is made known, which provides an ultrasound treatment in particular of the POME, so as to increased oil yield and at the same time a lower chemical oxygen demand (COD) of the depleted POME for traditional post-treatment in pond systems to reach. This proposal is likely to allow for a reduction in

Land use for the required ponds, but there is no evidence to use the nutrient and energy potential of the available POME quantities. WO 201 1/087202 A1 (2010) discloses a proposal for the treatment of the POME to obtain a useful oil sludge and reusable process water through the use of sequential phase separation, aerobic and anaerobic microbial treatment, filtration and reverse osmosis techniques. Without a verifiable label of the technical means for the utilization of the designated oil sludge, which may contain the vast nutrient and energy potential of the POME amounts used, the expert of this source can not take any workable steps for the material and energy recovery of the POME. US 2012/0040442 AI (2010) discloses a method for the treatment of POME, which initially provides the addition of butyrate and the subsequent anaerobic fermentation, preferably in the mesophilic environment. As a preferred apparatus technology for fermentation while the UASB fermenter technology is provided. Although indispensable steps for the energetic utilization of the POME by means of UASB fermentation technology remain unmentioned, the use of nutrient potential is not an object of the proposed method.

DE 10 210 034 135 AI (2010) describes a process for working up solid and liquid waste from vegetable oil production, which is the known hydrothermal carbonization, preferably at temperatures between 170 ° C and 320 ° C, at pressures between 5 and 15 bar , at pH values between 3.0 and 6.9 and at treatment times between 0.5 and 16 hours. This should also be from the liquid and solid production residues used in palm oil production a carbon-rich

Fe stofffraction and a wastewater fraction be recoverable. Whether and to what extent the wastewater from the carbonation process leads to more or less large demands on the wastewater treatment to avoid environmental damage is not described. Nor will be

Advice on using the potential of plant nutrients given. WO 2012/1 17537 A1 (201 1) describes a process for the biological treatment of wastewater from the extraction of palm oil by means of methane fermentation, in which the process of the invention is achieved by deliberately adding ash containing trace elements from the combustion of selected solid residues such as EFB, MF or KS POME fermentation should be improved.

It is known that the addition of trace elements is needed primarily in anaerobically operated stirred tanks, which are operated in the flow process. In these non-rinsing-out apparatus, an adapted mixed methane bacteria culture can only develop to a limited extent. Irrespective of this, methane fermentation by means of stirred and flow-operated apparatuses does not correspond to the developed state of the art and therefore can hardly meet the requirements for energetic use of the POME. Indications for recycling are completely missing.

EP 2 546 352 A I (201 1) contains the description of a technical solution which is used to reduce methane emission in the aerobic

Treatment of POME in palm oil mills. For this purpose, in several treatment steps under aerobic cultivation conditions from selected residues of palm oil production as

Carbon and nutrient source heterotrophic and / or mixotrophic

Microorganisms can be obtained, with the help of the combined anaerobic and aerobic treatment, the BOD content of the POME can be significantly reduced. The described technical solution is obviously primarily concerned with reducing the emission of

Air pollutants and less to the material and energy recovery of residues of palm oil production. Another proposal for the process engineering treatment of POME from palm oil mills is described in WO 2013/0621 17 AI (201 1). It is primarily about the reliable and cost-effective deposition of an oil-containing fraction from the resulting POME, by raising the temperature, the floating of the oil-rich phase is effected. So that the resulting scum of a suitable for this purpose

Absorbent be absorbed and can be obtained by a simple solid-liquid separation procedure wastewater with lower BOD contents. Undoubtedly, the separate use of the oil sludge obtained is a basis for the energetic utilization of the POME. The material

In contrast, recovery remains unaffected by this proposal.

WO 2013/169091 A1 (2012) discloses a proposal for POME utilization from palm oil mills, which initially provides for a pretreatment in the form of an oil separation and the subsequent methane fermentation of the depleted of an oil-containing phase POME fraction. In addition to the biogas to this proposal, the fermentation residues in a

Fertilizer usable fraction and in one of the membrantechnischen

Separate treatment accessible wastewater fraction, for example, to process the recoverable filtrate to boiler feed water can. In order to avoid biofouling, membrane technology systems contaminated with germ-containing biogenic substrates must be regularly treated with effective chemical agents, which is beneficial for the fertilizer technology of the nutrient-containing sludge as well as the utilization of the pure water fraction to boiler feed water precludes.

With WO 2014/1 12703 AI (2013) is a technical solution for

the treatment of both liquid and solid residues

revealed from palm oil production.

The almost complete material recycling of the residues is

According to the proposal achieved in that in a first recovery line POME cooled, neutralized and in terms of physical behavior

then, using fractionation, decantation and flotation steps, to recover a decanter cake and a liquid fertilizer. In a second recovery line, using the decanter cake obtained in the first line from the POME and the addition of MF, shredded CS, crushed EFB and KC, a mixed product is also prepared which is dried by hot air and in a powdered or powdered form as a solid fertilizer should be used. Apart from the economic and energetic dubiousness of this proposal, the energetic utilization of the main part of the organic dry matter contained in the residues is dispensed with. This leaves both the

economic opportunities because of insufficient exploitation of available energy potential and thus also the reserves for avoiding emissions of C0 ₂ eq from offsetting the use of fossil fuels.

WO 2015/156386 A1 (2015) describes a process for the separation of an oil / water emulsion with the aid of microbubble technology, with which POME can also be deflated by oily ingredients. notes to the

However, recovery of the recoverable sludge and aqueous fraction is lacking.

In addition to the technical solutions described in protective literature

can be proposals for solving the problem of material and

energy recovery of residues from palm oil production also from various company offers and technical publications. In the Jena Economics Research Papers 201 1 -037, a consideration of the potential for reducing emissions in the palm oil industry can be found with special consideration of the development of the nutrient potentials contained in the palm oil mills. This analysis shows that, given a total consideration of the energy expenditure for the operation of the plantations, the palm oil mills, the refining and the transport

(of palm oil) to Europe for different conventional scenarios by emissions of C0 ₂ -eq per MJ of fossil-produced palm oil between 40.0 and 45, 1 g C0 ₂ eq / MJ. In contrast, this value is reduced in the case of self-sufficient operation of the palm oil mill in the

Ideally, to a value of 13.4 g of C0 ₂ eq / MJ. However, this document does not indicate with which technical means the calculated ideal case can be realized.

By contrast, (2012) Camco International (http://waste-management-world.corn) informs about the development of energetic POME utilization using methane fermentation. A 13-year project aims to demonstrate that feeding Malaysian palm oil mills operators with energy that can be recovered from energy-efficient POM utilization into the supply network and marketing the resulting emission allowances is an option for improved efficiency , Information on the development of the nutrient potential contained in the POME can not be found in this information.

VEOLIA Water (www.biothane.com) (2012) publishes under the POMETHANE ^® brand a technical solution for the energy recovery of residues of palm oil production. This is an anaerobic biotechnological process in the thermophilic environment, which should be superior to previously known methane fermentation methods for POME in the mesophilic environment. The benefits would come from

- that the POME cooling can be dispensed with,

- that a maximum biogas yield can be achieved,

that shorter treatment times are required that more compact plant dimensions are achieved and

that the environmental impact can be minimized.

As a result, in a palm oil mill with a capacity of 60 t FFB / h, 770 m ³ POME would be produced daily. The recoverable electrical energy is given with a continuous power of 1, 2 MW. A COD reduction of more than 90% would be achieved.

It is clear to the person skilled in the art that in 700 m ³ POME of average quality, at least 45 t very finely divided and liquid organic dry matter are contained, which is prepared by means of a mature anaerobic fermentation technique

Biogas quantities with a calorific value of more than 310 MWh per day could be withdrawn. When recycling this amount of energy in usual

Combined heat and power plants with only 40% electrical efficiency, the recoverable electric power is more than 5 MW. There

it is known that the recoverable biogas results almost exclusively from the biotechnological degradation of the BOD contained in the POME, the described technical solution can achieve a BOD reduction of at least 20% and COD reduction of significantly less than 20% at best.

The Journal of Cleaner Production 44 (2013) fwww.eisevier.com/locate/iclepro) provides information on a current process of the Thünen Institute of Agricultural Technology for the recovery of POME and other residues of palm oil production. It provides the accumulating POME in one

Cool buffer and then fed to a methane fermentation in the anaerobic container system, preferably in fixed-bed fermenters. The resulting sludge should be thickened and composted with shredded EFB. The remainder of the fermentation residue is intended to be fed into an open pond system for the aftertreatment in the usual way. It is assumed that the mechanically difficult to perform EFB defibration task is solved and that a cost-intensive, low-emission closed composting technique is available.

The European International Journal of Science and Technology, Vol. 2, 2013 (www.cekinfo.org.uk) introduces an improved POME recovery process described for biogas production. Thereafter, the previously used uncovered pond systems are to be retrofitted by the use of a three-stage tank system, in the

the first stage primarily the intermediate storage, cooling

and distribution of POME quantities from the mill process, the second stage of primary fermentation and

the third stage of secondary fermentation

should serve. The biogas produced during the 14-day treatment period would have a methane content of 50%. The purified and compressed to about 10 bar biogas should then be subjected to a known Druckwasserwäsche for the separation of carbon dioxide and hydrogen sulfide. Thus, the recovered gas should be used either for the production of electrical and thermal energy as well as for vehicle refueling. However, information that goes beyond the general state of knowledge can not be found in this publication.

In the Asian Journal of Microbiology & Environmental Sciences Paper, Vol. 16, 2014 (www.envirobiotechiournals.com ^') discusses the POME recovery by anaerobic digestion. In the stepwise methane fermentation in the mesophilic milieu in successive areas, the most active microbial population in the inlet area then decreased

Activity future technical developments can be used. The description of technical solution steps are not included in this publication.

Through the CDM Executive Board of the UNFCCC / CCNUCC was the

Results Report No.13.1 of 01.04.2014 for the evaluation of the Kumbamgo POME methane capture project of the New Britain Palm Oil Limited published in Papua New Guinea. With the help of advanced technology for the

Recycling of about 1,100 m ³ POME daily is an annual

Emission reduction of about 63,000 t C0 ₂ eq can be achieved. The basis for this is, according to the proposal, the anaerobic treatment of the total amount of POME incurred in palm oil production, which is the Thin phase from the phase separation of the fermentation process

be removed added sediments. While the thick phase from this phase separation is intended for use as fertilizer, the liquid effluent from the anaerobic treatment should continue to be aftertreated in open ponds until the floodwater quality. It may be doubted that these simple measures will have an emission reduction effect in the

projected order of magnitude is achievable.

E.Quadrat GmbH (www.equadrat-gmbh.eu) informs in 2014 at a GIZ information event about a biogas project in Belitung,

Indonesia. According to the concept, 13,551 m ^{3 of} biogas with a methane content of about 52% by volume are obtained from 495 m ³ POME daily. The applied technical solution consists in this project, in particular in the cover of the individual pools of a conventional pond system for

accumulated POME quantities by per se known double membranes, in the use of facilities for circulation of the POME in the ponds, in the use of the available gas storage volume of about 15,000 m ³ and thus for stable energy gas utilization by gas engine combined heat and power plant technology. The realized with this technical solution electrical power in the amount of 1, 2 MW corresponds only to a rate of max. 35% of exploitable with known biotechnological agents energetic potential in the amount of at least 3.2 MW i _e ..

BioEnergy Consult (www.bioenergyconsult.com) explains (2015)

Recovery of POME by anaerobic digestion in

Fully mixed flow fermenters. In comparison between the usual POME treatment in pond systems, treatment should be anaerobic

operated fermenters may be characterized by the following effects, when at BOD contents between 25 and 66 g / 1 the COD content of the POME is between 44 and 103 g / 1:

- COD reduction = 97%

- Treatment time in the anaerobic system = 10 days

- Methane yield per kg COD = 0.2 kg Methane content of biogas = 55 Vol .-%

Solids discharge in the digestate = 8 g / 1.

The reported methane yield per kg COD is only about 66% of the achievable with known technical means result, which is why the claimed effect in the form of 97% COD reduction by the described technical solution is not plausible.

In http://biomassresearch.eu (2015) you can find the information about the

Biogas production from POME. After that, 80% of the

Greenhouse gas emissions from a traditional palm oil mill should be avoided if POME recovery is climate-neutral in closed

Fermenter systems would be done. While the recoverable amounts of biogas can be used for the process energy supply of palm oil mills, the resulting digestate should be used as fertilizer. On the

Possibility of opening efficiency reserves by influencing the content of dry matter, the pH and by using special microorganisms is pointed out. However, the information does not contain any indications as to which technical means should actually be used for the energetic and material recycling of the POME.

With the monitoring report of the Government often he Principality of

Liechtenstein (2015) on the project Univanich Lamthap POME Biogas Project (www.de.myclimate.org) discusses the effects of using

Recirculation technology documented in POME lagoons and their gas-tight covers. Thereafter, the resulting POME quantities pass through a cooling device to a mixing and equalizing tank, which is also fed DS from the crude oil purification. The drainage of the gas-tight covered lagoon reaches a smaller sized settling pond whose sediments are returned to the biogas process. Thereafter, the fermentation residues are treated in the usual way in pond systems to the Vorflutqualität. Indications of the achievable effects from the use of the energetic and material potentials, to reduce the land consumption for smaller ones

Pond systems and the achievable emission reduction are not derivable from the report. Hindawi Publishing Corporation (www.hindawi.com) provides information in the Journal of Combustion (Vol. 2015) on biogas production from POME and the effects of influencing biogas quality. Without up

To take particular account of process steps for biogas production from POME, such biogas is a CH ₄ content of 60% and a problematic

Inflammability and flame education attested. For this reason, technically generated hydrogen should be added to the biogas to compensate for these deficiencies.

The well-known technical solutions for the exploitation of POME are liable to the common lack that, in addition to the demonstration of usable resources from an effective utilization of POME and other biogenic residues of palm oil production for climate protection, for the production of energy from renewable sources and for recovering valuable economic implementable technical solution for the material and energy recovery of the POME can not be specified.

Object of the invention

The object of the invention is therefore to develop a technical solution by means of which the deficiencies of the known state of the art can be overcome. At the same time it is about the fulfillment of at least four

Objectives:

Firstly, the technical solution to be developed should enable the rational exploitation and utilization of the energetic potential contained in the available residues for energy self-sufficient palm oil production and for third parties.

Secondly, the nutrient potential contained in the residues should predominantly be concentrated in easy-to-handle organic multicomponent fertilizers with comparatively high concentrations of the main nutrients nitrogen, phosphorus, potash and sulfur and be returned to the economic cycle.

Third, the large-scale pond systems for the treatment of accumulating liquid residues should be at least partially saved.

Fourth, by means of achievable reductions of pollutant emissions from the avoidance of the use of fossil fuels, from the reduction of mobile transporter requirements, from the reduction of the use of chemical and / or mineral fertilizers, and from the lower land consumption for the required pond systems, incalculable contributions to the emission reduction of climate pollutants and for the increased demands on sustainability can be achieved. Description of the invention:

The object is achieved by a method according to claim 1. Advantageous embodiments of the invention are described in the subclaims. Thereafter, the material and energetic utilization of liquid and finely divided residues of palm oil obtained by treating these residues under exclusion of oxygen and by winning

Methane-containing biogas for energy recovery in gas engines or boiler plants. Here, the liquid residues are fed to at least one pretreatment with physical agents. This is the precondition for the fact that the aqueous liquid fraction, which after the pretreatment is particularly low in suspended matter and at least partially cooled, can be anaerobically treated with the aid of the known UASB fermentation technique.

On the other hand, the oil-and-dust-rich fractions of the liquid residues deposited in the pretreatment by the aqueous liquid fraction are subjected to a conventional methane fermentation known per se. The fibrous fermentation residues from the conventional methane fermentation are used for the recovery of a high-solids fertilizer fraction

Phase separation supplied. The biofilms obtained during the phase separation are fed together with the fermentation residues from the UASB fermentation technology to an inhibitor decontamination station. On the one hand, this procedure serves to avoid an increased inhibitor concentration, which has a toxic effect on the fermentation process, if an additional suspending agent in the form of available inhibitor-rich recyclates is required in the suspension of the feedstocks for the conventional methane fermentation. However, this procedure always serves to obtain a liquid fertilizer concentrate in the form of an aqueous ammonium sulfate solution and thus at the same time to reduce the COD load in conventional pond systems

post-treated wastewater. The biogas produced in the UASB fermentation and in the conventional methane fermentation contain as so called raw biogas besides methane and carbon dioxide too

Hydrogen sulphide. The resulting raw biogas is treated in a separate from the fermentation technology biological gas desulfurization station while obtaining a sulfuric acid process liquid. This not only serves to avoid climate damaging emissions of sulfur oxides in the energetic gas utilization, but also the return of the sulfur potential as fertilizer in the

Economic cycle. Using the sulfuric acid process liquid obtained in gas desulfurization in the inhibitor decontamination station, an aqueous ammonium sulfate solution is recovered as a liquid fertilizer. This has comparatively high levels of the plant-available nutrients nitrogen and sulfur. In the suspending station, the liquid suspending agents used are in particular the biofiltration rate, which is largely freed from ammonium in particular, and liquid fermentation residues of the UASB fermentation from the inhibitor decontamination station. With the help of this technical solution according to the invention task in a particularly economical manner, the designated four effects are achieved:

The vast majority of biotechnologically exploitable energy potential is used in the form of a largely desulfurized biogas for direct energy recovery in combined heat and power plants, in gas and steam turbine combinations and / or in steam boiler plants. That in the

The inorganic nutrient potential contained in the residues used is used in the form of the solid phase from the phase separation of the fermentation residues of conventional methane fermentation, which contain the major part of the plant nutrients phosphorus, potassium, calcium and magnesium and a proportion of nitrogen and sulfur. The contained in the raw biogas

Sulfur compounds and the ammonium nitrogen contained in the fermentation residues of the UASB fermentation and in the biofilters of the phase separation station are used as aqueous ammonium sulfate solution in the

Received inhibitor decontamination station for plant fertilization.

The biogas withdrawn from the residual materials used and the resulting fertilizer components on the one hand reduce the BOD and COD load of the biofiltration rate from the phase separation and the conventional post-treatment biofilter Fermentation residues released from inhibitors from UASB fermentation and, on the other hand, the climate damage hitherto accepted through the adequate use of fossil energy sources and chemical or mineral fertilizers as well as the emission of climate pollutants in conventional waste treatment. Proportional to the withdrawal of

organic and mineral shares from those proposed

The requirements for the area required for the aftertreatment of the liquid fermentation residues in Pond systems are also reduced if they are still used to achieve the required Vorflutqualität.

In a preferred embodiment, the pretreatment of the liquid residues by means of flotation and oil separation technique, preferably using a Druckentspannungsflotation and / or a combined oil and suspended matter separation by Plattenseparatoren performed.

According to a further embodiment, the UASB fermentation of the pretreated liquid residues is carried out in a thermophilic or mesophilic environment. Because of the experience of only slight fluctuations in the POME quality, the choice of a thermophilic environment is possible, at least in the case of UASB fermentation, without overstraining the comparatively sensitive thermophilic cultures. At the same time, the

technical and energy requirements for the cooling of the POME quantities often incurred with temperatures of more than 80 ° C can be reduced. It is also possible, the fermentation residues from the UASB fermentation preferably by downstream DENI technology to usable process water

reprocess or nachzubeteln in known Pond systems to the required Vorflutqualität.

In a further embodiment of the invention is provided in the

process stages

Oil separation of the POME,

- suspended matter separation of the POME,

mechanical crude oil purification using decanter technology,

Separating the autoclaved FFB into palm kernels and EFB,

Separation of the palm fruit meal in crude oil, palm kernels and MF or Separation of the palm kernel regrind in palm kernel oil, KC and KS accumulating residues with higher levels of anhydrous substance

to the necessary extent in one

Inhibitor Entfrachtungsstufe treated digestion residues from the UASB fermentation and / or Biofiltraten from the phase separation station to suspend and then treated multi-stage using adapted Methanbakterien- mixed cultures anaerobically. Here, the multi-stage anaerobic treatment using at least one hydrolysis step, a

Main fermentation, a Nachfermentationsstufe and / or a digestate storage are performed. Preferably, at least one of the anaerobic treatment stages takes place in the thermophilic environment. In the interest of a more extensive degradation of the organic ingredients available

Residues with POME larger contents of anhydrous substance, it is possible to perform at least one of the anaerobic treatment stages batchwise. This measure can primarily longer

Minimum treatment times are guaranteed in the fermentation process. In addition, such a measure will make a significant contribution to

Development and to obtain selected and adapted germs in each batchwise fermentation stage obtained, even if the predominantly in use fully mixed container systems are used.

In another embodiment, it is possible to use the aqueous

Ammonium sulfate solution from the Hemmstofentfrachtstation with

to use the predominant potential of plant-available nitrogen and sulfur contained in the residues used directly for plant fertilization. Alternatively, however, the aqueous ammonium sulfate solution from the Hemmstoffentfrachtungs-station with the press cake from the

Phase separation station combined and used as organic nitrogen-potassium phosphorus-sulfur fertilizer for plant production, preferably in the oil palm plantations.

In an energetically particularly advantageous variant, it is also possible to cool the POME from the current palm oil production to the selected treatment temperature in the UASB fermenter station and parallel to the

Heating the digestate from the UASB fermenter station and / or of the biofiltrate from the phase separation station to the temperature of the

Ammoniumaestreibers the Hemmstoffentfrachtungsstation of about 60 ° C to perform a heat exchange. This leads to both technical and energy savings in the required cooling processes as well as to reduce the energy costs of operation of the expeller in the Hemmstoffentfrachtungsstation.

embodiment

The invention will be explained in more detail below with several embodiments.

In the attached drawing show

Fig. 1: the simplified block diagram of a fiction, designed according to

Biogas plant for the use of POME and Decanter-Sludge;

2 shows the simplified block diagram of an inventively designed

Biogas plant for the use of POME and Decanter-Sludge, in which the fermentation stage for the suspended residues with a

upstream hydrolysis stage is completed;

the simplified block diagram of an inventively designed biogas plant for the use of POME and Decanter-Sludge, with a preparation line for obtaining finely divided EFB, MF and / or

KC is supplemented as additional starting materials.

Example 1 :

According to FIG. 1, 23 liquid residues of palm oil production 1 in the form of POME 22 and finely divided residues in the form of DS 29 are to be recycled in a palm oil mill for the processing of 300,000 t FFB per year

be recycled energetically. Available are 150,000 t / a POME 22 with an average of 6.7% dry matter content and 12,500 t / a DS 29 with an average of 28% dry matter content. The liquid residues of the palm oil production 1, 22 are supplied to a pretreatment with physical means 2 in the form of a pressure release flotation 19. In this case, a liquid fraction obtained after the pretreatment of the liquid residues from the palm oil production 1 in the form of a low-floating flotate 3 from the flotation station 19.

This flotate 3 is by means of a UASB fermenter station 4 with a

Usable volume of a maximum of 2,000 m ³ at medium treatment times of about Treated anaerobically for 5 days and at least 2 days in a UASB fermenter 4. The deposited in the flotation station 19 from POME 22 shares 5 in the form of accruing

Flood-rich flotate sludge, together with the available finely divided DS 29 in a suspending station 16, becomes a fibrous slurry

Biosuspension processed. To set an optimal dry matter content between 12 and 15% in the biosuspension liquid suspending agent 17 in the form of biofiltrate 18 and the liquid fraction 3 from the flotation station 19 is added to the extent necessary, the previously in the Hemmstoffentfrachtungsstation 12, the vast majority of the contained ammonium in the form of a aqueous ammonium sulfate solution 15 was removed. The biosuspension obtained in this way is now fed to a conventional methane fermenter station 6. The conventional methane fermentation 6 is characterized by the use of anaerobically operated fermentation tanks with a useful volume of at least 3,000 m ³ , in which the fermentation substrate is circulated by mechanisms, by gas injection and / or hydraulically. That in the UASB fermenter station 4 and at the

conventional methane fermentation 6 resulting raw biogas with levels of hydrogen sulfide of more than 3,000 ppm is in a biological

Desulphurization gas desulfurization 13 so far that the gas desulfurization station 13 leaving biogas contains only hydrogen sulfide contents of 10 ppm maximum. At the same time, sulfuric acid process liquid with a pH between 1.4 and 1.7 is obtained in gas desulphurisation. With their help, the ammonia-containing vapors produced in the expeller of Hemmstoffent- freighting station 12 at more than 50 ° C in a downstream washing column in the form of a Rieselkörperapparates be washed at temperatures of less than 25 ° C. The resulting aqueous ammonium sulfate solution 15 with a pH between 3.5 and 4.5 can be used directly as a liquid nitrogen-sulfur fertilizer. In the example, however, this fertilizer is the in the phase separation station. 9

sprayed on solid-rich fertilizer fraction 8, so that now a nutrient-rich multi-component fertilizer with high concentrations of nitrogen, phosphorus, potassium and sulfur compounds is available. Of the 150,000 t POME used per year, 19,700 t / a of flotation sludge 5 and 143,000 t / a of flotation 3 are recovered in the flotation station 19. From the flotate 3 are in the UASB fermenter station 4 at a middle

Residence time of 5 days per year about 1 1,500 t of raw biogas with one

Energy content of about 61 GWh and about 131,500 t of liquid fermentation residues 11 produced. The 12,500 t DS 29 per year are suspended with the 7,000 t of flotation sludge 5 from the flotation station 19 and about 1,000 t biofiltrate 18 with lowered ammonium contents from the inhibitor decontamination station 12 and fed to a conventional methane fermenter station 6. There, the fermentation substrate with a mean residence time of about 48 days, a quantity of raw biogas of about 4,200 t / a with an energy content of about 22 GWh / a withdrawn. The remaining fermentation residues 7 in the amount of 26,300 t / a are separated in the downstream phase separation station 9 to about 7,500 t press cake 8 with about 30% dry matter content and 18,800 t / a biofiltrate 10. The 18,800 t / a biofiltrate 10 obtained in the phase separation station 9 and the 131,500 t / a fermentation residues 11 from the UASB fermenter station 4 are in the

Inhibitor decontamination station 12 fertilizer concentrates extracted in the form of an aqueous ammonium sulfate solution 15 in the amount of about 6,000 t / a. Of the inhibited process liquids, 1 1,000 t / a is considered

Suspending agent 17 returned to the conventional methane fermenter station 6, so that in total only about 139,300 t / a of liquid residues in conventional Pond systems 21 must be post-treated. While without the technical solution used in the example the Pond-System 21 a total of 150,000 t / a POME 22 untreated with a content of

56,000 mg / 1 BOD * 150,000,000 1 / a = 8,400 t BOD / a

and 81,000 mg / 1 COD * 150,000,000 1 / a = 12,150 t COD / a

would be supplied, the now in the Pond system 21 nachzubehandelnden residual liquids in the amount of 139,300 t / a significantly reduced

Oxygen consumption potential.

The BOD reduction is at least apparent

a) in the UASB fermenter station 4 in which there from the contained

organic potential formed biogas with a BOD reduction of about 5,350 t / a and b) in the conventional methane fermenter station 6 proportionally from the

Flotate sludge in the biogas formed there with a BOD reduction of about 250 t / a.

The resulting BOD reduction thus reaches about 5,600 t / a and thus more than 65%. The COD reduction results from the withdrawal

Plant nutrients prior to introduction of the residual liquid into the Pond system 21. With a COD-dissolved of 25 kg / m ³ , the 150,000 t / a of the POME 22 fed to the exemplary treatment will be neutralized by the average of the inorganic nutrients nitrogen, phosphorus, Potassium, calcium, magnesium and sulfur amounting to about 4.3 kg / t in the form of aqueous ammonium sulfate solution 15 from the Hemmstoffentfrachtungsstation 12 and in the form of high-solids fertilizer fraction 8 from the phase separation station 9 about 3.7 kg / t for the return to the Economic cycle discharged. This reduces the COD-dissolved load for mining in the Pond System 21

150,000 t / a * 3.7 kg / t = 555 t / a.

The total COD reduction in the Pond system 21 thus reaches about 70%, which reduces the performance requirements of the Pond system 21 to about 30% of the initial situation.

Example 2:

According to FIG. 2, as in Example 1, 150,000 t of POME 22 and 12,500 t of DS 29 are recycled materially and energetically each year with the aid of the technical solution according to the invention. Unlike in Example 1, the recovered from 7,000 t / a in the flotation station 19 flotation 5, 12,500 t / a DS 29 and 1 1,000 t / a biofiltrate 18 from the Hemmstoffentfrachtungsstation 12 in the suspending station 16 produced biosuspension prior to use in a conventional Methane fermentation station 6 spatially from both the main fermentation stage 31 and the Nachfermentationsstufe 32nd

supplied to separate hydrolysis 30. The predominantly active in this hydrolysis stage 30 hydrolyzing bacteria lead to the pre-acidification of the biosuspension, whereby the container capacity in the downstream

Fermentation stages 31, 32 is available primarily for the methanation activities. This leads to an increased degradation in the

Biosuspension contained organic substance, connected to an increased biogas yield and an increased concentration of inorganic plant nutrients in the digestate 7. The biological desulfurization station 13, the biogas from the UASB fermenter station 4, the hydrolysis 30, the main fermentation stage 31, the Nachfermentationsstufe 32 and the gas-tight digestate storage 33 are now supplied. The gas store, which is spatially separated from the UASB fermenter station 4 as well as from the conventional methane fermenter station 6, which in the example is designed as a double-membrane reservoir, is now used extensively for the temporary storage of desulfurized biogas, resulting in

Reduction of the emission of odorous mercaptans due to the inevitable diffusion of such sulfur compounds through the plastic membranes used leads.

Example 3:

According to FIG. 3, as in Example 1, the 150,000 t / a POME 22 produced in a palm oil mill for the processing of 300,000 t FFB 23 per year, and the 12,500 t / a DS 29 are treated according to the invention. In addition, however, now also 70,000 t / a EFB 24, 45,000 t / a MF 25 and 7,500 t / a KC 26 are used. The quantities of KS 27 also accumulating in the palm oil mill will continue to be used as high-energy fuels in addition to the

marketed palm oil. In this case, the suspending station 16 is preceded by a crusher station for obtaining an additional finely divided fiberized feedstock. To obtain a biosuspension with an average dry matter content of 15%, the

Suspendierstation 16 next to the shredded EFB 24 and MF 25, the available 7,000 t / a of flotation sludge 5 from the flotation station 19 for the resulting POME volumes 22, the 12,500 t / a accumulating DS 29 and 270,000 t / a

Suspending liquid 17 fed from the Hemmstoffentfrachtungsstation 12. The biotechnological treatment of the resulting biosuspension with very low tendency to segregation now takes place in a conventional biosuspension

Methane fermenter station 6. This is a total of four gas-supplying

Treatment stages, the hydrolysis stage 30, the main fermentation stage 31, the Nachfermentationsstufe 33 and the digestate storage equipped. The

Hydrolysis stage 30 and Nachfermentationsstufe 33 are batchwise operated. The hydrolysis step 30 is operated at a medium temperature of 50 ° C on average. While the main fermentation stage 31 is operated at an average of 41 ° C. in the mesophilic environment, the treatment in the secondary fermentation stage 32 takes place in the thermophilic environment at an average of 53 ° C. The total useful volume of the containers for the active anaerobic

Treatment levels 30, 31, 32 is at least 60,000 m ³ .

In addition to the amount of energy collected in the UASB fermenter station amounting to 61 GWh / a and 131,500 t / a of liquid fermentation residues 11, 6 biogas quantities are mixed with one in the conventional methane fermentation station

Energy content of another 285 GWh / a, and 357,000 t / a fermentation residues 7 generated. From these digestates 7, 122,000 t / a are obtained in the phase separation station 9 in the form of a high-solids fertilizer fraction 8 with an average of 30% dry matter and 235,000 t / a of biofiltrate 10. The fermentation residues 11 from the UASB fermenter station 4 arrive together with the biofiltrate 10 from the

Phase separation station 9 in the Hemmstoffentfrachtungsstation 12. With their help, in addition to the aqueous ammonium sulfate solution 15 about 366,000 t / a of inhibitor-loaded liquid suspending agent 17 are provided. Of this, 268,000 t / a was recycled as a process in the

Suspendierstation 16 must be used again, leaving only the difference of 98,000 t / a than nachzubetelnde in the Pond system 21

nutrient-poor aqueous fraction and thus only 65% of the original amount of POME to be treated 22 and only 70% of the remaining according to Example 1 quantity requirement to the Pond system 21st

LIST OF REFERENCE NUMBERS

1 - liquid residues of palm oil production;

2 - pretreatment of liquid residues by physical means;

3 - liquid fraction after pretreatment of the liquid residues from the

5 5 palm oil production;

4 - UASB (Upstream Anaerobic Sludge Blanket) fermenter station;

5 - separated portions of the liquid residues of palm oil production;

6 - conventional methane fermenter station;

7 - digestate from the conventional methane fermenter station;

0 8 - high-solids fertilizer fraction;

9 - phase separation station;

10 - Biofiltration rate during phase separation;

1 1 - digestate from the UASB fermenter station;

12 - inhibitor decontamination station;

5 13 - biological gas desulphurisation station;

14 - sulfuric acid process fluid;

15 - aqueous ammonium sulfate solution;

16 - suspending station;

17 - liquid suspending agent;

0 18 - biofiltrate after treatment in the inhibitor depopulation station;

19 - flotation station;

20 DENI (denitrification / nitrification) station;

21 - Pond system;

22 - POME (Palm Oil Mill Effluent);

25 23 - FFB (Fresh Fruit Bunches);

24 - EFB (Empty Fruit Bunches);

25 - MF (Mesocarp Fiber);

26 - KC (Kernel Cake);

27 - KS (Kernel Shells);

30 28 - adapted methane bacteria mixed culture;

29 - DS (Decanter Sludge);

30 - hydrolysis step;

31 - main fermentation stage;

32 - post-fermentation stage;

35 33 - digestate residue storage;

Claims

1. Process for the material and energetic utilization of liquid and finely divided residues of palm oil production by treatment of these residues under exclusion of oxygen and extraction of methane-containing biogas for energy recovery in gas engines or boiler plants, characterized

the liquid residues (1) are supplied to at least one pretreatment (2) by physical means,

in that the aqueous liquid fraction (3) available after the pretreatment (2) is anaerobically treated by means of a UASB fermenter station (4) such that the portions (5) of the liquid residues (5) separated from the aqueous liquid fraction (3) during the pretreatment (2) 1) one

be subjected to biotechnological treatment in a conventional conventional methane fermenter station (6),

that the fermentation residues (7) from the conventional methane fermenter station (6) are fed to a phase separation station (9) serving to obtain a solids-rich fertilizer fraction (8),

that in the phase separation station (9) resulting biofilm rate (10) and / or the digestate (1 1) from the UASB fermenter station (4) a

Hemmententfrachtungsstation (12) are supplied,

that in the UASB fermenter station (4) and in the

Conventional Methanfermenterstation (6) resulting methane and hydrogen sulfide-containing biogenic gases in a spatially separated from the fermenter stations (4, 6) biological

Gas desulphurisation station (13) are treated while obtaining a sulfuric acid process fluid (14),

by using the sulfuric acid process liquid (14) in

Anesthetic decontamination station (12) an aqueous

Ammonium sulfate solution (15) is recovered and

that in the suspension stage (16) as a liquid suspending agent (17) are used in the first place, in particular of ammonium substantially liberated feedstocks (1 1, 18) of the Hemmstoffentfrachtungsstation.

2. Method according to claim 1, characterized

in that the pretreatment (2) of the liquid residues (1) is carried out by means of the flotation station (19) and the oil separation technique, preferably using a pressure-release flotation (19) and / or a combined oil and suspended matter separation by means of plate separators.

3. The method according to at least one of claims 1 and 2, characterized

in

that the treatment in the UASB fermenter station (4) is carried out in a thermophilic or mesophilic environment. 4. The method according to at least one of claims 1 to 3, characterized

in

that the digestate (1 1) of the UASB fermenter station (4) in a

Downstream DENI station (20) prepared to usable process water or post-treated in known Pond systems (21) to the required Vorflutqualität.

5. The method according to at least one of claims 1 and 2, characterized

in

that in the process stages

- Oil separation of the POME (22),

- suspended matter separation of the POME (22),

- mechanical crude oil purification using decanter technology,

- separating the autoclaved FFB (23) into palm kernels and EFB (24),

- Separation of palm fruit meal in crude oil, palm kernels and MF (25) or

- Separating the palm kernel ground material in palm kernel oil, KC (26) and KS (27), resulting residues are combined with levels of solids, suspended and then treated in several stages using a selected and / or adapted methane bacteria mixed culture (28) anaerobically.

6. The method according to at least one of claims 1 to 5, characterized

that the multi-stage anaerobic treatment is applied at least

* a hydrolysis step (30),

* a main fermentation stage (31),

* a Nachfermentationsstufe (32) and / or

* a digestate storage (33)

is carried out and that at least one of the anaerobic

Treatment steps (30, 31, 32, 33) takes place in a thermophilic environment.

7. The method according to at least one of claims 5 to 6, characterized

in

in that at least one of the anaerobic treatment stages (30, 31, 32, 33) is carried out batchwise.

Method according to at least one of claims 5 to 7, characterized

that the aqueous ammonium sulfate solution (15) from the

Hemmstoffentfrachtungsstation (12) is used with the vast potential of plant-available nitrogen and sulfur contained in the residues used directly for plant fertilization.

9. The method according to at least one of claims 5 to 6, characterized

in

that the aqueous ammonium sulfate solution (15) from the

Hemmstoffentfrachtungsstation (12) with the press cake from the

Phase separation station (9) and as an organic nitrogen-potassium-phosphorus-sulfur fertilizer for plant production,

preferably in the oil palm plantations, is used. Method according to at least one of claims 1 to 9, characterized

that for cooling the POME (22) from the current palm oil production to the selected treatment temperature in the UASB fermenter station (4) and for heating the digestate (1 1) from the UASB fermenter station (4) and / or the biofiltrate (10) the phase separation station (9) to the temperature of the ammonium expeller of Hemmstoffentfrachtungsstation (12) of about 60 ° C, a heat exchange is performed.