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FERMENTATION THE TASK PROCESSES TECHNOLOGIES THE ENTIRE SYSTEM


PREPARATION FOR FERMENTATION

01 01 Separately collected biodegradable household waste 02 Restaurant leftovers 03 Expired food from supermarkets and market waste 04 Food industry waste

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THE TASK Fermentation with biogas production is the “royal road� of biological waste treatment. It results in a high-quality fuel that can even be refined into vehicle fuel. This fuel is renewable in every sense of the word, and contributes to both environmental and climate protection. Biodegradable waste from households, commerce and industry can be processed by natural means to recover as well energy as materials. A fermentation system does both.

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The origin of the input material makes it very heterogeneous, which creates special challenges. Processing is needed to turn this into a material that is simple and economically viable to ferment. Komptech machines are in use around the world to help to handle this task. Our products are at home in all major fermentation plant process steps.


PREPARATION FOR FERMENTATION

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Komptech GmbH Komptech is a leading international manufacturer of machines and systems for the mechanical and mechanicalbiological treatment of solid waste and biomass, and for the processing of woody biomass for use as a renewable fuel. The product range comprises over 30 different types of machines, which cover the key steps in waste handling and biomass processing. All share a practical focus and pioneering spirit. Practical focus means that they are designed around our customers’ needs, not our own. Pioneering spirit means working towards the future by further cultivating our accustomed high development expertise.

EXPERTISE Two key processes for organic waste fermentation The pulper process In three steps, waste is turned into a pumpable ferment liquid for wet fermentation. About 90 percent of the input goes into the ferment. 1) Shredding 2) Pulping 3) Wet screening The press process In three steps, waste is turned into a pumpable ferment and compostable dry matter. About 50 percent of the input goes into the ferment, the remainder to composting. 1) Shredding 2) Dry screening 3) Pressing

Technology for a better Environment

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PREPARATION FOR FERMENTATION

01 Shredding 02 Pulping with heavy matter separation

THE PULPER PROCESS

THE PULPER PROC

This process giving the maximum y

03 Wet screening

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04 Sand separation 05 Pressing of oversize fraction

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Undersize fraction

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All figures in percentage by weight 4

Sand < 1%

Ferment liquid 90%

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PREPARATION FOR FERMENTATION

SHREDDING

PULPING

WET SCREENING The pulper process A defined process with precisely coordinated machines results in a liquid that is ideal for fermenting.

CESS

yield for fermentation

The schematic shows the solution developed by Komptech. It is ideal for separately collected biodegradable waste, food scraps, expired foodstuffs and food industry waste. Shredding (01) at low speed opens up the organic material and prepares it for liquefaction. In the pulping step (02) the shredded material is turned into a liquid that can be separated in the subsequent wet screening step. Heavy contaminants are removed.

Oversize fraction

In wet screening (03) an oversize fraction and light contaminants are separated out. In sand separation (04) abrasive fines are removed from the ferment liquid.

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Pressing (05) mechanically dewaters the oversize fraction with light contaminants. The ferment liquid is now ready for biogas production.

Light contraries < 10%

Heavy contraries < 1% Technology for a better Environment

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PREPARATION FOR FERMENTATION

01 Shredding 02 Dry screening 03 Pressing

THE PRESS PROCESS

THE PRESS PROCE

PROCESSING FOR FERMENTATION AND

04 Sand separation

Liquid 04

All figures in percentage by weight 6

Sand < 1%

Ferment liquid 45%


PREPARATION FOR FERMENTATION

SHREDDING

DRY SCREENING

PRESSING The press process A defined process with precisely coordinated machines separates a ferment liquid from compostable solids and contraries.

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AND COMPOSTING

The schematic shows the press process developed by Komptech. The press process is ideal for mixed garden and kitchen waste, as well as expired packaged foodstuffs.

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Shredding (01) at low speed opens up the organic material and prepares it for subsequent screening.

Oversize fraction

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Screening (02) removes large contraries from the shredded material.

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Pressing (03) is the central component of the process. It separates out a fluid for fermentation and a solid component for composting.

Solid

In sand separation (04) abrasive fines are removed from the ferment liquid. The ferment liquid is now ready for biogas production.

Solids 45%

Contraries < 10% Technology for a better Environment

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PREPARATION FOR FERMENTATION

SHREDDING (PULPER AND PRESS PROCESSES)

• High throughput for materials of all kinds • Powerful intake with long counter-rotating shredding drums • Variable particle size range (60 - 120 mm) through simple screen basket changes

shredding

• Resistant to contraries Precise shredding through slow drum rotation

The task Biodegradable, often contaminated waste needs to be reduced to below a maximum particle size to reduce the danger of blockages. Contraries like packaging need to be shredded as gently as possible for subsequent screening. The solution The Crambo is a low-speed, two-shaft shredder that meets these needs precisely.

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A wide range of blade and screen basket variants mean that it can handle practically any application. It even opens small packaged food items effectively yet gently. In detail In extreme cases, the Crambo can shred 200 l steel drums of organic waste, for fully automatic processing by the pulper method.


PULPER (PULPER PROCESS)

PREPARATION FOR FERMENTATION

• A range of container volumes for different throughput rates (8 - 16 m³) • Heavy material sluice for stones, metal etc. • High turbulence through high energy input (10 kW/m³)

PULPER Pulping to pumpability The task The waste needs to be turned into a material with the right consistency for subsequent screening. It cannot exceed a certain viscosity, so that the oversize fraction can be screened out of the ferment liquid. Packaged items need to be separated into content and packaging material.

After a treatment process period that depends on the material, the fluid is sent on to wet screening. In detail A heavy material sluice periodically removes specific heavy items, such as metal, glass, bone, stones and ceramics. This protects downstream machines from damage and excessive wear.

The solution In the pulper, waste is thinned with liquid and mixed at high turbulence in batches, to achieve the required viscosity level.

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PREPARATION FOR FERMENTATION

WET SCREENING (PULPER PROCESS)

• Removes all large contraries from the ferment liquid • High throughput for up to three pulpers • Precise separation • High flexibility through stepless adjustment of particle size

WET SCREEN

• Patented automatic Cleanstar cleaning system

Wet screening with exact particle size The task To produce a contrary-free pumpable ferment liquid, the pulp needs to be screened in the 10 - 20 mm range. High throughput and low maintenance effort are the most important requirements for this key machine in the pulper process. The solution The Multistar wet star screen reliably removes large contraries out of the ferment liquid. As a star screen, it takes only little space and screens to an exact size, with a higher viscosity pulp than other systems.

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In detail The Multistar wet screen gives trouble-free continuous operation at a screening size that is adjustable at the press of a button. The patented Cleanstar cleaning system keeps the screen gaps clean throughout operation.


PRESSING (PULPER PROCESS)

PREPARATION FOR FERMENTATION

• Maximum ferment liquid yield • Minimal contrary content • Minimal abrasion of ferment liquid

PRESS & DESANDER Post-processing for higher quality The task Two materials need to be removed. The amount of light contraries (film, fibres etc.) needs to be reduced by dewatering and separation from organic material sticking to it. The sand also needs to be removed from the ferment liquid to minimise abrasion and wear in the downstream stages of fermentation. The solution A screw press first thickens the screened oversize fraction and compresses it until it is drip-free.

The liquid is added to the ferment liquid. A settling tank collects the sand from the pulp. In detail The amount of oversize fraction and sand removed from the pulp depends on the input material. The oversize fraction is between 5 percent with food scraps and 15 percent with mixed garden and kitchen waste. Normally the sand will be less than 1 percent.

Technology for a better Environment

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PREPARATION FOR FERMENTATION

DRY SCREEN (PRESS PROCESS)

•T  rommel or star screen as desired •D  ependable removal of contraries before pressing

DRY SCREEN Dry screening of contraries

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The task The press process requires that the shredded material be screened to < 80 mm before it goes to the downstream screw press.

In detail The screened contraries can’t interfere with the functioning of the system, and include the bulk of the materials originally put in the wrong waste container (plastics).

The solution A trommel or star screen can be used to screen off contraries over 80 mm. Either type of machine will do the job competently, so the downstream machines can do theirs.

The amount of > 80 mm oversize fraction depends on the choice of Crambo screen basket. If there is a low amount of wronglybinned material, a small screen basket size can be chosen to minimize the amount of oversize fraction, and vice-versa.


PRESSING (PRESS PROCESS)

aufbereitung PREPARATION FOR für die vergärung FERMENTATION

• Parts coming in contact with material are of corrosion-resistant steel (except for the press screw) • Wear-resistant tools for long life

screw press

• Different screen baskets for different degrees of pressing

Pressing into solid and liquid The task Pressing splits the material into a liquid for fermentation (ferment liquid) and a solid for composting. The output materials should meet the requirements for downstream handling as closely as possible. The solution The mash separator was developed by Komptech specifically for this application, and is the key machine in this process. A conical screw compresses the material by a factor of 1:7 and presses it through a screen cylinder.

The solid escapes through an annular gap at the end of the screw. The ferment liquid runs through the 1 - 2 mm slits of the screen cylinder. In detail The ratio of ferment liquid to solids depends on the starting moisture and structural content of the input material. For example, mixed garden and kitchen waste with 60-70 percent water content is pressed out into a solid with a 55 percent water content.

Technology for a better Environment

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PREPARATION FOR FERMENTATION

PREPARATION FOR FERMENTATION

• Sizes from small single-shift plants to industrial-scale three-shift operations • Supplemented by proven components from wellknown manufacturers • Conveyors, pumps, pipelines, steel structures, exhaust-air cleaning • High-quality output

THE ENTIRE system Integration of all components Komptech is a central component vendor for builders and operators of fermentation plants - shredders for precise shredding, wet and dry screens, pulpers, presses and sand separators. We also develop and supply systems of connected and linked machines especially with the pulper and press processes for material preparation for wet fermentation.

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Komptech has the expertise and capacity to fit out fermentation plants with complete system solutions, from input material to the desired end products.


PREPARATION FOR FERMENTATION

EXPERTISE IN ALL FERMENTATION PROCESSES

WET FERMENTATION

CONTINUOUS DRY FERMENTATION

DISCONTINUOUS DRY FERMENTATION • Preparation for wet fermentation • Preparation for continuous dry fermentation • Preparation for discontinuous dry fermentation

EXPERTISE IN ALL PROCESSES Dependability for fermentation Renewable energies are the future of world energy supply. Fermentation plants create biogas and electricity from waste. Around the world, Komptech help do this, highly reliably.

In shredding, pulping, screening, pressing and sand separation, our machines provide for smooth, fully automated waste treatment operations for fermentation plants.

Komptech machines are used in all fermentation processes, wet as well as continuous and discontinuous dry fermentation.

Whether kitchen scraps, mixed garden and kitchen waste, expired food or biodegradable waste from the food industry, Komptech has the ideal solution.

Technology for a better Environment

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Technology for a better environment

Komptech GmbH Kühau 37, A - 8130 Frohnleiten [t] +43 3126 505-0 [f] +43 3126 505-505 [e] info@komptech.com Komptech UK Ltd. Forge End, Lodge Farm Kineton Warwickshire, CV35 0JH [t] +44 1926 64 29 72 [f] +44 1926 64 29 71 [e] info.uk@komptech.com

www.komptech.com We reserve the right to make technical changes in the course of ongoing development.

E2012


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