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CASE STUDY I SEPTEMBER 2018
PIGERRY CAMPAIGN
ACTI-Mag
ACTI-Mag™ on an anaerobic cogeneration plant at a piggery farm.

By: Michael Romer

                       CASE STUDY SNAPSHOT                     

 

   CHALLENGES

To increase profits by reducing chemical consumption and increasing power and biogas generation.

To improve biogas quality and quantity and reduce odors due to H2S.

To reduce blockages due to struvite formation.

To reduce chemical usage and inculcate environment-friendly solutions.

 

    SOLUTIONS

Improves biogas quality and quantity.

Reduces H2S, thus reducing odors.

Reduces soluble phosphate levels and struvite build up.

Does not add salinity to soil and improves SAR values in the soil.

Is non-corrosive, environment-friendly and safer to handle.

 

  BENEFITS

The production of biogas was increased by 30%, having improved quality with increase in Methane (CH4) by 19%.

The average production of energy increased by 15%.

A significant increase in earnings ($68K) was achieved from increased power generation and reduced chemical

The average levels of H2S were largely reduced by 70%.

The average daily effluent soluble phosphate levels decreased by 40%.





INTRODUCTION

ANALYSISACTI-MAGBIOGAS

Anaerobic Cogeneration Plant

Introduction

Piggery Location:
South West Victor

 

Objectives:

  • Reduce H2S in biogas from existing 700 ppm
  • Avoid the use of a chemical scrubber
  • Generate more biogas
  • Generate more power
  • Reduce retention time
  • Reduce blockages from struvite
  • Safe product to handle
  • Reduce Sodium Hydroxide consumption

South West Victoria Piggery

 


 

Wastewater process

Wastewater process

 


 

Before trial power generation

Before trial power generationGenerator: 1300MWh Per year

Thermal power: 214KWth Hour

Electricity: 192 kWh

 

The wastewater stream volume is reduced to 100,000 litre per day which goes though the anaerobic system.

 

Breakup:

  • 35,000 Litre from the DAF
  • 65,000 litres from the solids screens

 

Typical analysis going into the anaerobic system

Typical analysis going into the anaerobic system

 


 

Initial laboratory testing comparing different alkalis

Test Method

 

equal amounts of activated sludge

+ equal amounts of wastewater stream

+ equivalent dose rates of tested alkalis

= average biogas volume generated measured over a 4 day period.

 

Initial laboratory testing comparing different alkalis

 

For the same alkalinity dose, ACTI-Mag resulted in 300% more biogas generation.

 


 

 ACTI-Mag™ BENEFITS VERSUS CAUSTIC SODA OR LIME?

  • ACTI-Mag is safe to handle
  • Non corrosive
  • Safe for the environment
  • Does not add to salinity
  • Improves SAR value in soils

 

Why use ACTI-Mag versus caustic soda or lime?

 


 

Phosphate removal & struvite formation

Phosphate removal & struvite formationACTI-Mag helps locking up phosphates and ammonia in the wastewater stream by forming struvite:


Mg2+ + PO43- + NH4+ -----> MgNH4PO4*6H2O

 

Phosphate removal & struvite formation

 

The average daily effluent soluble phosphate levels decreased by 40% when dosing ACTI-Mag.

 


 

Hydrogen Sulphide H2S levels

Trial started on the 24/8/2015.


The piggery used ferric chloride and had a normal raw biogas H2S levels around 700-500ppm.

 

Hydrogen Sulphide levels


Since introduction of ACTI-Mag, the average levels of H2S were reduced by 70%.

 


 

Average monthly biogas production

Same effluent production - (7,620 sows equivalent)

 

Average monthly biogas production

 

ACTI-Mag increased biogas production by 30% on average.

 


 

Monthly energy production (Kwh)

Same effluent production - (7,620 sows equivalent)

 

Monthly energy production (Kwh)

 

ACTI-Mag increased power production by 15% on average.

 


 

Gas Quality



Gas Quality

ACTI-Mag increased CH4 by 9%

 


 

Typical versus actual biogas production

Typical versus actual biogas production

Ref: Analysis of energy production costs from anaerobic digestion systems on US livestock production facilities. Oct. 2007.

 

Analysis of energy production costs from anaerobic digestion systems on US livestock production facilities. Oct. 2007.

 


 

ACT-Mag, INCREASE REVENUE FROM YOUR WASTEWATER
REDUCE COSTS AND INCREASE PROFITS

Case Study increased earning per year from power generation using ACTI-Mag

 

reduce costs and increase profits with ACTI-Mag

 

- Cost of the ACTI-MagTM per year = $11 k

+ Savings from removing chemicals from the scrubber (due to reduced H2S) = $10 k

= Total increase in earnings using ACTI-Mag $68 k / year



 

Creating new materials, solving global challenges.

 

Calix Australia - Creating new materials, solving global challenges.

 

Contact Calix

 

(02) 8199 7400

 

info@calix.com.au

9 Bridge St, Pymble NSW 2073