Biogas Laboratory Setup in Foz do Iguaçu, Brazil
Contents
1. 1 C calibrated Firma INCOTERM Barometer Barometer Standard equipment Resolution 0 1 hPa Precision 3 hPa Firma TESTO The laboratory includes the main equipment required for performing the batch tests e g cabinet dryer muffle and eudiometer set images 1 2 and 3 Parts of the equipment arrived during the training such as the heating system for the fermenter and one balance The gas analyzer Drager for reading the biogas composition was one of the most important equipment not available during the training During the first test the composition of the gas was not measured Materials such as the components of the confined liquids and the digital thermometer with a decimal place are still to arrive Image 1 Cabinet dryer Image 2 Muffle Image 3 Eudiometer In general terms the available equipment allows the start of a first experiment to check the quality and the characteristics of the equipment but the manufacturer gives none guarantee for their accuracy For this purpose cellulose from the BOKU as well as cellulose from Brazil and sugar will be used The numbers of eudiometer systems allow an analysis of one sample 3 of 12 digester have to be used for the inoculum and 6 of 12 for the internal standards cellulose and sugar Experiments with more than one sample are not feasible at the moment 1 1 1 Considerations about laboratory structure Gas exhaust system the cabinet dryer and the muffle have no2. Qu Universit t f r Bodenkultur Wien University of Natural Resources and Life Sciences Vienna Biogas Laboratory Setup in Foz do Igua u Brazil 3rd Progress Report August 2011 Debora Fistarol Lyson Ram n Engu danos Requena Alexander Bauer Barbara Amon Thomas Amon Content 1 Set up and beginning of operation of the fermentation laboratory at the Observatory 1 ILI GENEI OVS VIG EMEN m 1 1 1 1 Considerations about laboratory StructUre ccccccsssccccssececeseccccesecceeeeseceeeuecessueceesenes 1 1 2 Considerations about CQUIPMENL ccccsssececeeseccccescceceesececeeseceeceeeceeseuecessunecetsuneceesenes 1 2 Suggestions from BOKU side to optimize the FPTI laboratory cccccesscccceeseceeeeseceeeeeseeeees 4 2 Introduction into fermentation laboratories second stage journal 1 3 Adjustment of the handbook to the specific needs of the fermentation process in subtropical climates Task 3 2 e ARRA 19 4 Overview of the Project Status 49er Nee re 23 5 Attachments eere able Nee 24 1 Set up and beginning of operation of the fermentation laboratory at the Observatory 1 1 General overview Basic equipment for batch experiments according to VDI 4630 are availed in the laboratory in Foz do Igua u Table 1 shows a list of lab equipments suggested by BOKU as
3. 300 kWh the maximum permitted by law From our point of view the difficulties are o Lackof temperature control in the system There is no heating in winter thus a reduced production is recorded during this season image 27 In summer it produces too much biogas and has therefore to combust gas on a regular basis o Lacking efficiency of the substrate mixing system The blend is conducted via a pump and a tube with a diameter of 10cm The bottom of the fermenter needs to be regularly every two years cleaned since it accumulates a layer of solid material o Loud noise from the power house which is located near the household and the animal husbandry o Lacking professional support to optimise the process Week 3 Sampling of inoculum for experiments Inoculums were gathered in 2 different outlets of the biogas plant as to characterise the substrate One of the outlets is located after the main fermenter image 31 and the other after the secondary fermenter UP xS Ras n g Image 31 Outlet after the main fermenter Dry matter content determination new substrate and repetition of first analysis The new inoculum will be tested and previous analysis will be repeated Activities Monday 18 07 Meeting with Ms Matinc and Ms Freiberger general laboratory use and organisation and quality management We noticed that in the past two weeks the work of two colleagues from FPTI laboratory was often interrupted due to
4. as to allow a control of the internal temperature of the fermenter The test was performed during the day and the temperature changes were controlled hourly The adjustment was on an individual level since all of them presented different temperatures and some exceeded 40 C on the lowest adjustable level 1 the temperature of some fermenters was adjusted to the required value of 37 5 C until late afternoon The following day a different value should be noticed Preparation of UNILA s crucibles Crucibles of an adequate size were provided by UNILA as a loan They were prepared and stayed in the muffle for 6 hours at a temperature of 1100 C Meeting There was a meeting with the new FPTI CEB head Ansberto do Passo Neto and Caroliny Matinc Eliza B Freiberger Ramon Enguidanos and Debora Lyson Mr Passo Neto introduced himself in this meeting as head of the CEB Centro de Estudos de Biog s do FPTI This study group was created approximately 6 months ago and its objective is to concentrate on the research and development of the biogas production Mr Passo Neto explained that the CEB is divided into three different areas such as 1 development of biogas production with regional agricultural producers taking the micro basin project of the Ajuricaba river as an example 2 Development of the FPTI laboratory project 3 Development of the biogas plant pilot project within the Itaipu Dam as to use human dejections rests from restaurants as
5. different reasons such as unexpected visits tasks assigned and constant telephone calls We explained the necessity to work without interruptions in the laboratory as to obtain reliable results in the analysis We proposed that 1 any visit should be scheduled 2 the tasks assigned shall comply with a priority and it is necessary to draw the attention of their supervisors to the consequences that an assigned task in a certain moment may harm the analyses and the reliability of the laboratory 3 phone calls need also comply with a priority and must not interfere with the course of the analysis Calculation demonstration BOKU chart general A general statement on the BOKU chart was given which needs to be filled in and the data are repeated automatically an automation of the analysis quality control Calculation demonstration methane efficiency A profitability analysis regarding the methane conversion including results on BOKU s elementary analysis was made Demonstration and praxis of silage in laboratory for experiments with energy crops The cut of grass in the Itaipu area was brought to the lab for silage The material was pressed in a 2 liter container sealed and stored in the refrigerator The time for finalising the silage process will take 2 months Sample preparation of fresh mass in the vacuum equipment The same material was prepared in vacuo to observe the results The results of the conservation will be visible with
6. programming device Explanation about when to stop the experiment Daily production may be lower than 196 of total production Showing where can also be checked on the excel file Control and monitoring the experiment Reading off daily gas production Collection of data and input into the excel file Stirring fermenters Fermenter 2 2 and 2 3 both filled with cellulose PTI broke while stirring Glass shows to be really thin and fragile Decision to stop stirring fermenters with current system Both fermenters belong to the same unit therefore we cannot accept the results from only one fermenter Cellulose PTI rejected Monitoring room temperature Climate control unit broke down during the night Order to buy two electrical heaters Room temperature difference ranges between 20 C at 08 00 and 24 C at 18 00 Activities Control and monitoring the experiment Reading off daily gas production Collection of data and input into the excel file Monitoring room temperature Turning on electrical heaters Testing different parameters to adjust the room temperature at 26 C Isolation of laboratory Laboratory room completely separate from the offices Initially the laboratory and offices were separated by a wall closing half of the height of the room Now the wall rise up to the roof Ventilator exit was sealed up Meeting with a climate control company Description of laboratory requirements concerning temperature Development of a project to
7. stage of the introduction phase Activity 4 Setup and begin of operation at the fermentation laboratory counterpart facilities Task 4 1 Set up and beginning of FTPI support 31 Aug 2011 August 2011 finished operation at the fermentation BOKU laboratory Observatory Task 4 2 Fermentation laboratory BOKU amp FPTI training second stage Activity 5 Monitoring of the overall process Task 5 1 Set up of a help desk at BOKU 31 Aug 2011 Website forum the contractor s http biogas forumprofi de amp hotline phone was set up Task 5 2 Conduction of inter 31 Aug 2011 See Report 1 2 chapter 1 3 laboratory tests Task 5 3 Assistance in obtaining BOKU 31 Aug 2011 See Report 1 2 chapter 1 2 the ISO certification Elaborating a roadmap to achieve certification Task 5 4 Calibration of the 31 Aug 2011 See Report 1 2 chapter 1 3 laboratory according to European standards and establishment of connections to the EU biogas network 23 5 Attachments e User Manual e Joint Advanced Research Program FPTI BOKU 24
8. well as available equipment in the Laboratory in Foz do Iguacu All chemicals needed for the production of the sealing liquid are available Table 1 List of required and available laboratory equipment facilities measuring instruments consumption goods Step Lab Equipment Recommended Brand Available Brand Specifications in Foz di Sample preparation Milling Mixing Cutting Mill B chi Mixer B 400 ye o ool Mixer Cross Beater Mill SK X00 Dry matter Cabinet dryer Standard equipment digital temperature control and thermostat of security Firma Maroni Organic dry Muffle furnace Standard equipment Precision of matter temperature control configurable microprocessed controller Firma QUIMIS Water content Karl Fischer Mettler Toledo V20 Titrator Balance Capacity 120 g Resolution 0 0001 g Firma MARK 214TH BEL Start of experiment Storage tank Tank Yes inoculum Peristaltic pump Verderflex EV8000 Digital control and frequency changer Firma PROVITEC mE Balance Standard equipment Capacity 4200 g Resolution 0 001 g Firma SHIMADZU Standard equipment Resolution 0 001 pH Precision 0 005 Firma TECNOPON Batch experiments Selutec Eudiometer http www selutec de Yes equipment LN Sy 0000 Heating Heating System http www selutec de Beg d Gas Portable gas Drager X am 7000 analyzer Thermometer Thermometer Standard equipment Digital precision
9. with N Initial value and first reading Tuesday Eliza and Caroliny monitoring the experiment 02 08 Water and temperature control Gas production reading Collection of the data and input into the excel file View of the Experiment 16 Wednesd ay 03 08 Thursday 04 08 MERE L a m com nl e i SS T e T i i k ft a By 4 n i ru EX Ji na A Sa i wa La Image 43 view of the experiment Stirring each fermenter for half an hour mixing every unit at the same time Decision to mix every unit once per day in the morning after reading Checking how the system works Working on excel files Identification of mistakes on the tables and graphics due to leaks temperature variation etc Interpretation of graphics and results Explanation of different therms such as specific methane yield specific biogas yield specific biogas production of sample material and where are they located in the Excel file Review of process to calculate the pressure correction factor cell location in Excel file and influence in the results Visit from a TV program to record the laboratory and talk about the projects carried out at PTI and BOKU Control and monitoring the experiment Eliza and Caroliny monitoring the experiment Water and temperature control Reading off daily gas production Collection of data and input into the Excel file Working on the manual Writing the procedure of dry matter and volatile solid
10. Ansberto mentioned the idea to hire another worker with agriculture background studies for future projects End of training 3 Adjustment of the handbook to the specific needs of the fermentation process in subtropical climates Task 3 2 19 The user manual which has been developed in this project was carefully revised and discussed in different points in order to clarify doubts related to definitions and to the applied terminology The study of this manual was realized in three steps In the third step Ricardo Steinmetz from EMBRAPA participated and contributed to the adaptation of the manual with the characteristics of the subtropical climate The points which have been discussed are as listed below Table 4 Table 4 Question and discussion points of FPTI with remarks and comment of BOKU Questions discussion points doubts 1 Definitions Degree of degradation DD in Biogas yield Quantity of biogas in liter per quantity of substrate feed in kilogram Biogas formation potential There was a doubt regarding the concept abbreviated tests Chemical oxygen demand COD in mg COD I Measure of the content of oxidizable compounds in the gt substrate Parameter used to esteem the content of organic matter in the sample Fermentation Doubt about the meaning of the term product in the case of fermentation Fermentation test See gt batch test a test which complies with the recommendati
11. The thermoelectric plant consists in complementary projects A grain dryer was set up near the central energy generator image 20 aiming at drying the cereal production of producers who participate in the project This implies an economic benefit of up to 3096 of the grain s value It is a circular dryer with an approximate diameter of 6 meters and a bottom part with orifices allowing a passage of heated air The air is heated by two types of renewable energy in systems that are still under development One of them is the combustion of biogas in a furnace that heats up the air that is conducted to the dryer image 21 The other one is made via a solar heating system that stores the heat by means of a plastic canvas leading the heated air in a tubular form to the dryer image 22 Image 20 Grain dryer Image 21 Furnace for Image 22 solar combustion of biogas heating In both properties we visited a collection of inoculum was realized At the outlet of the fermenter on the pig farm property were gathered about 5 litres of material On the cattle farm we gathered the same quantity of material from the secondary storage tank The aim of this collection in different locations was the characterization of the substrate by defining the dry matter volatile solids and the bacteria s activity In both cases eudiometers were used The biogas plants we visited function at room temperature Thus the inoculum was transported to the laboratory at room temperatu
12. a flow and the water will be lost only in a small cover with a diameter of 25cm that remained quantity The inoculum must be free of visible solid partially open as to prevent a concentration of material gas This led to an excessive loss of water Possible causes A The original substrate contained too much dry matter content B It was stored in a recipient with a large cover In order to avoid gas pressure it was partly opened and lost too much water as well 3 The biogas plants do not have a heating 3 A solution needs to be discussed at BOKU system Due to this reason the bacteria are not adapted at a constant temperature of 37 5 C and the inoculum cannot be used for laboratory experiments This occurs mainly in winters Temperature of fermenters Situation FPTI laboratory has bought 12 magnet stirrer and heating plate equipment for the batch experiments This equipment was suggested by BOKU The reason for this decision was to be an option to the Selutec Eudiometer set mainly due to the homogenisation possibility of the substrate The equipment was tested and it appeared not to be adequate for the experiments Problem Suggestions 1 The temperature scale is shown on a scale 1 Installation of a water bath with a heating system from O to 10 and so it is very difficult to define and a thermostat the ideal range for the experiment 37 5 C 0 5 C 2 The equipment has no thermostat i e it is 2
13. ctric energy producing central Image 14 Fermenter and gas Image 15 Secondary storage Image 16 Purifier collector tank for moisture and solid particles Description of the biogas plant at the cattle farmer The following property we visited is destined for beef cattle farming It is a small producer with approximately 20 animals The biogas plant model was developed in this region and offers a sump image 17 a fermenter image 18 a gas collector and a storage tank for depositing fermented material The solid particles and the straw are separated from the substrate in the sump before entering the fermenter The fermenter consists in two containers as illustrated in fig 5 One of them is subterranean and is located under the superficial fermenter After the fermentation process the substrate is thrown into the lagoon that deposits the fermented material The fermented material is led periodically to the field which then acts as a biofertilizer Similar to the previous property the generated biogas is purified with regards to solid particles and moisture before it is sent to the central that produces electric energy and which is located outside the property Image 17 sump Image 18 fermenter The biogas produced in the 34 properties included in the project is sent to the thermoelectric plant then it is purified and transformed into electric energy via a generator of 100 kVA 100kW image 19 Image 19 Electric generator
14. d of plastic material in order to put the magnet stirrer into a piece of plastic as we have at BOKU to obtain a better mixing Laboratory temperature during the day ranges between 22 C 24 C During the night decrease to 18 C 19 C We order a climate 15 control unit with thermostat to start test on Monday Week 5 Activities Monday Talk with Alexander and Debora 01 08 discussion about calculation ratio inoculum substrate and questions about materials Talk with Eliza and Caroliny about the importance of being methodical and concentrate during the start clarifying steps to follow and everyone s task Turning on equipment warming up water Start with the experiment Printing the file with the calculated amount of substrates Cellulose BOKU Cellulose PTI Sugar Filling in the substrate and writting down the real amount Same filling system as BOKU storage tank with controlled temperature of the inocullum at 37 5 C Mixer in it running while filling in the fermenters Pipe in the storage tank is located at the middle level of the tank to obtain a representative sample Pipe is connected through the peristaltic pump with another pipe to fill in the fermenters Accurate weights obtained Taking three samples from the inoculum at three different times for its dry matter analysis to check homogeneity of inoculum in all units a wh A Image 41 Substrate weighting Image 42 Tightness test with N AR Tightness test
15. e Internet even if in German only Anyhow it is not applicable as Brazil has to follow its own local and regional laws Homogeneity and inhomogeneity The term material was change into sample 20 The degree of homogeneous or inhomogeneous distribution of a characteristic value or material in a quantity of material Zero sample zero test The Portuguese translation the term Amostra zero was changed to Amostra de branco 1 1 Abbreviation Liter In Brazil the standard abbreviation to Liter is L So it was used L instead 2 Organic substances Term waste disposal In the Portuguese translation the following term has been changed disposi o de dejetos to disposi o de res duos This was made because this is a term of more expanded denotation 2 1 Sampling They are a reflection of their homogeneous Exclusion of the term inhomogeneous because the inhomogeneous or heterogeneous feature definition is included in the term heterogeneous structures a knowledge of which is of fundamental importance to the quality of sampling The sampling process consists of taking a Inclusion of the term population that shall allow a number of small samples from a large aggregate better understanding sample population Organoleptic sensory examination The terms grain size and grain distribution are Type of material origin and composition translated as granulometria Consistenc
16. e analysis performed exceed the required limit and need therefore to be repeated The reason is based on the material s heterogeneity making the ideal mixture difficult Hand book revision and adjustments 3 part see table 4 With the participation of Ricardo Steinmetz of EMBRAPA Thursday Preparation of the fermenters to the new heating system All 12 fermenters were mounted on the same side of the bench Two glass containers to 14 07 store water were ordered One of them arrived and the test started with the magnet stirrer and heating plate equipment A higher water level could control the temperature while using 3 heating systems for a container with 6 fermenters Calibration of the eudiometers and filling the columns with sealing liquid Mr Steinmetz from EMBRAPA who performed the calibration of the eudiometers asserted that the equipment purchased by FPTI provides a millimetric metering within the acceptable patterns allowing reliable results Filling the columns with sealing liquid Another step within the preparation to the fermenter s tests was the filling of the eudiometer columns with the confined liquid Testing the inside pressure of the eudiometer and calculation of the corrector factor According to the VDI 4630 the results from the produced biogas volume need to be without pressure which results from moisture To obtain this result a correction in the metering is required This correction is performed by a metering
17. e test was taken Decision to cancel the test Visit to Colombari biodigestor Visit to Colombari biodigestor to collect more inoculum pig manure seeding Taking samples from exit biodigestor and exit biodigestor Il in order to compare results between them and previously collected samples regarding dry matter volatile solids analysis and activity test Arrival to the laboratory Storing the material at 37 5 C Testing peristaltic pump Pump provided with electronic device to control rotation speed and time Checking different values in order to optimize the required amount of inoculum to be filled into the fermenter 200 g with the most accuracy possible Explaining how to organise the equipment before start filling showing how to fill the inoculum into the fermenter and how to connect the pipe into the storage tank to obtain a homogeneous and representative sample Pump works properly Image 37 Image 37 Test with the peristaltic pump Image 38 crucibles Preparation of material for analysis First preparation of material for analysis crucibles Numbering every cup for its subsequent identification image 38 and putting into the muffle for 6 hours at 1100 C Dry matter analysis To determine properties of Inoculum Put into the oven 3 replicates from each material Warm up to 60 C for 6 hours and then up to 105 C for the whole night Creating files in Excel and Word document to print and collect data gas measurement gas a
18. ed by Debora Fistarol Lyson and Ram n Engu danos Requena during a period of three and five weeks respectively The training in the fermentation laboratory processes started on July 5 2011 The program of the second stage is shown in Table 2 Table 2 Training second stage in the fermentation laboratory processes Week 1 Activities Tuesday 05 07 Wednesd ay 06 07 Equipment and laboratory structure revision On the first day of the training a control of the available equipment in the laboratory FPTI was done A detailed report about the considerations and suggestions respect structure and equipment is on point 1 Set up and beginning of operation of the fermentation laboratory at the Observatory Inoculum evaluation The available inoculum was checked about the conditions of capture and storage It was decided to bring a new substrate on Tuesday Table 3 shows the suggestions from the BOKU about inoculum to collect and storage Week schedule Presentation A presentation of the EU AGROBIOGAS website and the general applications by FPTI laboratory took place This calculation tool was developed by KTBL and optimized during the European Project EU AGROBIOGAS coordinated by BOKU between 2007 and 2010 A data base was made available including the results of the 12 project partners The tool allows estimations for the methane production of different materials as well as for the costs and the final revenue This presentation inc
19. g to the VDI standards Analyze of data dry matter content and volatile solids determination as demonstrated before Data demonstration form A model for a laboratory report was presented based on a BOKU report The colleagues may use it as a template to develop their own model Preparation of the second water container After receiving the 2 water container we were able to finalize the preparation of the experiment start Temperatures between 36 5 C and 38 5 C have been measured This means an oscillation above the expected values according to the manual but still within the limits suggested by VDI 2 C The strict criteria described in the manual are coming from actual results of European institutions The new heating system with sensor and thermostat was not yet available Therefore the fermentation test was started with the actual heating system 10 Image 34 2 Eudiomether sets Eudiometer onside pressure A test conducted to measure the internal pressure of the tube which replaced the dammed one Calculation Based on the amount of volatile solids the amount of material which was necessary for the fermentation test was calculated Start of the first experiment The measuring tubes have been prepared and properly closed in order to avoid the exhaust of gas The water temperature of the container was controlled accordingly The substrates have been weighted directly in the fermenters The fermenters have been filled u
20. gas exhaust system The laboratory will change its location to a new construction in October 2011 Due to this reason there was no need for great investments in the structure of the actual laboratory room although a gas exhaust system will be installed in the new room Our recommendation was to build a gas exhaust system in any case since inhaling gas emission from the cabinet dryer and muffle is dangerous to the health of the laboratory workers Air temperature the room temperature was not controlled A room thermometer was not available and the existing heating system in the room was not used Image 4 The room is not accurately closed there is a permanent exchange between the outside and inside air by means of two ventilators on the wall Image 5 Doe to great differences in temperature during the day middle min 9 C and middle max 23 C in winter the quality of the results will be influenced negatively Recommendations to the new laboratory 1 A control to maintain the air temperature without major oscillation Therefore it is necessary that the walls are duly isolated a heating and air conditioning system will be installed 2 Air circulation should be avoided as it may modify the temperature of the substrates and thus influence the results Image 4 air conditioning Image 5 ventilator on the wall 1 1 2 Considerations about equipment All available equipment is listed in table 1 Some equipment arrived during the training
21. ified that this depends on the size of the fermenter In the case of FPTI the fermenter is able to receive up to 200 ml of inoculum The doubt was regarding the fact that the material has to be mixed constantly The experience of the BOKU lab showed that even test without any shaking provided good results The continuous shaking shows also disadvantages as e g the disagglomeration of bacteria colonies In any case it depends on the tested material The question was the expected pH value It was explained that an optimum pH is 7 5 22 4 Overview of the Project Status Status Timeline Activity amp description Organization Activity 2 Preparation of the ground for setting up the lab Task 2 1 List of all necessary Finished Finished laboratory equipment facilities measuring instruments consumption goods and chemicals Task 2 2 Identification of BOKU amp FPTI Finished Finished manufacturing companies and sources of supply Activity 3 Handbook and introduction to the fermentation laboratory Task 3 1 Procedures and working BOKU 31 Jan 2011 Finished instructions handbook Task 3 2 Adjustment of the BOKU amp FPTI 31 Jan 2011 August 2011 finished handbook to the specific needs of the fermentation process in subtropical climates Task 3 3 Experiments BOKU amp FPTI 31 Jan 2011 Finished Implementation of the processes at the operational level in an existing fermentation laboratory First
22. in 2 months Volatile solids determination as described above Out of the tested inoculums the material coming from the Colombari farm provided the high test dry matter content and volatile solids 2 88 DM and 1 66 VS Calculation demonstration specific methane production The calculation of the specific methan production was demonstrated by using the volatile 19 07 solids values Fermentation test with the different substrate to inoculum The 4 different inoculums were placed into the eudiometer for fermentation with the aim to observe the gas production Out of the 4 tested inoculums the the level of gas production of the Colombari inoculum was similar to the levels of gas production of inoculums used at the BOKU Therefore we decided to use this inoculum in the Batch test Sealing test change of 2 columns In parallel the gas tightnesssistem was tested by using nitrogenic gas 2 measuring tubes showed gas leakage due to a production fault One of them could be changed against a tube of BOKU With a total of 11 devices one of the testes was reallised with only 2 repetitions Gas exhaust at muffle and cabinet dryer was installed A team of 2 technicians installed the system which was needed for the gas exhaust of the drying in the cabinet dryer and the muffle Image32 Muffle Image 33 Cabinet dryer Wednesd Calculation demonstration Buswell formula ay 20 07 The use of Buswell s formula was demonstrated accordin
23. in four levels of different internal pressures and using Excel a diagram is to be elaborated including a linear regression line The formula obtained by this line indicates the correction factor Visit to the Colombari farm swine breeding and biogas plant Mr Colombari possesses 3000 to 5000 animals pigs Pig farming produces a total of 1200 m liquid manure per day Images 24 and 25 Image 24 Pig farming Colombari Image 25 Pig farming Colombari The biogas plant following the Canadian model possesses 2 fermenters both with a gas tank a secondary lagoon storage place Fig 26 27 and 28 The retention time amounts to 32 days After the expiration of this time the liquid manure of the biogas is transferred to the storage places and carried regularly to the fields There are no data regarding the content of the substrate neither input nor output Once a year the soil and water are subject to control Image 26 Mr Colombari Image 27 second level Image 28 Storage tank and Ms Matinc FPTI in fermenter secondary storage tank front of the main fermenter For safety reasons he uses two compressors image 29 one of the compressors pushes the biogas to the motor and the other towards the combustion of the additional biogas image 30 Image 29 Compressors Image 30 Protection The reactor has 100kWh produces 75 kWh and is served by 50m biogas h Mr Colombari is willing to optimise his system as to produce up to
24. is also weighed into the fermentation vessel mixed if necessary with water and the vessel then carefully filled with inoculum to the desired volume Regular mixing such as shaking the vessels each day to fully resuspend the sediments and the scum layers will suffice 5 2 End of the experiment Inoculum and substrates to be analysed were fermented for about min 40 days in an eudiometer under anaerobic conditions and control of the pH value The partner has asked for examples of materials with easily degradable organic components It was stated that in agriculture generally all components without lignocellulosic complex are easily degradable organic components The standardized inoculum is a substrate with basic characteristics for the fermentation test It has to have bacteria with low activity to make sure that the results of the tested samples are not distorted In the Portuguese translation the following terms have been changed Experimentos Batch to Experimentos de batelada The following questions came up Why is the limit for the temperature oscillation given in the manual 37 5 C 0 5 C is more rigid than then recommendation of VDI 4630 37 C 2 C Explication was given that this limit is BOKUs own experience based on recent research results which also has the support of other European research institutions The question rised up which is the desired volume We have clar
25. isolate completely and control temperature conditions Meeting with Ansberto Caroliny and Eliza to discuss about which analysis can be carried out by PTI and which can be order to external laboratories like EMBRAPA or the department of chemistry from University UNILA attached to ITAIPU Control and monitoring the experiment Reading off daily gas production Collection of data and input into the excel file Monitoring room temperature Review of formulas and calculations for DM and VS analysis Review of tables Drager Explaining how to use the gas analyzer how to collect the data and put it into the file Showing where can be checked the specific methane yield 18 Wednesd Control and monitoring the experiment Reading off daily gas production Collection of ay 10 08 Thursday 11 08 Friday 12 08 data and input into the excel file Monitoring room temperature Visit to Agri Energy Cooperative for Family Farming Ajuricaba Micro Basin Case located in the town of Marechal Candido Rondon Guided visit along the whole area of fields farms and gas pipelines leading to a thermoelectric micro center images 45 and 46 Image 45 Ajuricaba 1 Image 46 Ajuricaba 2 Connected to the thermoelectric plan a grain dryer and gas purifyer filter are under construction Visit to a cattle and pig farm talking with the producers about their experiencies showing the procedure to storage the sludge the way to feed the biodigestor peri
26. luded the password to allow FPTI laboratory the access to the home page This calculation may serve as a basis for the comparison of the evaluation of the results Finding options regarding the heating of the inoculum outside the dryer There was a need to find options for the heating and to keep the inoculum s temperature during the test set up One available apparatus was equipped with a container for heated water at a temperature controlled by a connected thermostat The test consisted in transferring the heated water through the hose to a larger container images 9 and 10 Subsequently the inoculum was positioned directly in the container This system allows the heated inoculum to be kept at the required temperature even while the fermenters are filled E Image 9 inoculum heating system Image 10 inoculum heating system V al Another possibility to store the inoculum is an equipment for bacterial culture Image 11 Thursday 07 07 allowing the storage of up to 3 containers 5 liters of inoculum with a controlled temperature Image 11 bacterial culture equipment Revision of the manual and adjustments 1st part see table 4 Visit to the Condominio de Agroenergia da Micro Bacia do Rio Ajuricaba Agroenergy condominium of the Ajuricaba river micro basin a Pilot Project coordinated by Itaipu images 12 and 13 amp rraiPo E33 MARECHAL LX DARE L PESEHV L VENTO Image 12 Project plaque Image 13 Informa
27. nalysis temperature control etc Working with Eliza and Caroliny on excel files Explaining the aim of each file links between them describing which data has to be manually inserted by them and which is automatically calculated by Excel Looking through calculations and formulas Listing step by step how to put the data in and order to follow for every stage of the experiment DM and VS analysis ratio and amount of substrate calculations gas measurements etc Thermostats received Installing the system heater sensor and thermostat together with an electrician from PTI System was composed of heater and sensor connected to the thermostat Programming thermostats at 37 59 C with a variation range 0 4 images 39 and 40 14 DEN Zu ni Image 39 heat system Image 40 heat system and fermenters Testing the system Installing water stirrers in both pools Heating system works properly without significant temperature variations between fermenters Thursday Dry matter 28 07 Putting the samples from the oven into dessicator for one hour Measuring output weight and write it down in the table Volatile Solids analysis Putting the sample into the muffle Increasing temperature from environmental temperature up to 250 C gradually in 3 hours Then increasing immediately up to 550 C and maintining it for 4 5 hours Let the muffle turned on at 105 C along the night due to high humidity and not having enough time to mea
28. odicity and amount of feeding retention time Talk with the biodigestor manufacturer Pedro Kohler about the possibility to install a pipe with a tap into the biodigestor to collect easier the inoculum for its subsequent analysis Control and monitoring the experiment Reading off daily gas production Collection of data and input into the excel file Review of training schedule Reading through every point Listing which were satisfactory carried out Listing points which were not satisfactory achieved and reason for future discussion between PTI and BOKU such as Karl Fischer titrator not received Drager results analyse not received conclusion of Batch Test not enough data research planning strategy future discussion Laboratory climatization is expected to be completely controlled within the next weeks Dr ger gas analyzer is expected to come in the beggining of September Use of it was shown and cleared Selutec equipment is expected to come in the middle of September New experiments with the new equipment are planned to start in the end of September Control and monitoring the experiment Reading off daily gas production Collection of data and input into the excel file Recommendations for future experiments with a larger number of samples and eudiometers Need to find a bigger and proper storage tank under controlled temperature conditions to prepare and storage the inoculum Work on methodology for analysis and start of the tests
29. ons of DIN 38414 8 or if not doing so which is precisely documented Fermentation trial Gas yield Formation of gas About German Waste Disposal Act AbfAbIV Remarks comments explanations Inclusion of the acronym DD and of the formula DD Co C C x100 where C zinitial concentration and C final concentration Inclusion of the unity liter and kilogram should be more exact Explication was given The concept of abbreviated tests refers to the calculation of the theorical potential of the biogas production based on the elemental composition of the material Inclusion of the sentence Parameter used to esteem the content of organic matter in the sample In this context the term product refers to biogas The text was grammatically not understood Therefore the meaning of the text was explained and another suggestion for the text is presented and may be as follows Suggestion for translation See batch test a test which complies with the recommendations of DIN 38414 8 or alternatively has to be documented precisely It was questioned why the terms fermentation and fermentation trial is listed separately We decided to maintain both terms in the manual because both may be found in the literature It was the same problem as above Both terms Gas yield and Yield should be maintain in the manual as both terms may be found in the literature This law text is available in th
30. others are still not available FPTI has ordered an optional Eudiometer system at Selutec which has still not arrived This system needs to be calibrated The Eudiometer set is composed of 12 units allowing an analysis of 1x inoculum 2 internal standards cellulose and sugar as well as of 1 additional sample Fermenter heating system the heating system is part of the eudiometer apparatus from Selutec This equipment was still not available Due to this reason an optional heating system towards the own Eudiometer set was required Images 6 and 7 Unfortunately the FPTI colleagues decided to order 12 magnet stirrer and heating plate equipment without consulting us This equipment is not ideal for this purpose since 1 it does not resist a constant use 2 does not allow an exact temperature control that is required for the present tests Image 8 3 there is no thermostat connected to switch the equipment on and off according to the required temperature But we made a test when the ordered equipment arrived One of them was available Prior to the training the colleagues from FPTI laboratory performed a test with the equipment nevertheless an exact temperature control was not considered to be necessary Image 6 heating system Image 7 Image 8 heating system control fermenter on top of the heating system Thermometer for substrate there are 2 types of thermometers one is digital and the other is a mercury thermometer The digital the
31. p a Brazilian biomass database in the area of biogas production At the end of the meeting it was suggested to write a letter of intent for a new agreement between ONUDI EMBRAPA FPTI ITAIPU and BOKU Image 36 Meeting participants from left to right Airton Kunz EMBRAPA Debora Lyson BOKU Ricardo Steinmetz EMBRAPA Eliza Freiberger FPTI Cicero Bley back FPTI Caroliny Matinc in front FPTI Ansberto do Passo Neto FPTI Marcelo A de Souza FPTI Ram n Engu danos BOKU Activities Monday 25 07 Monitoring test Reading off daily gas production Water level and temperature control Importance of controlling these parameters on Fridays and Mondays before and after the weekend Not significant evaporation in both pools Monitoring temperature Different temperature between pools 2 C 36 C 38 C All heaters do not work in an homogeneous way and is impossible to have an accurate temperature control in both pools Previously to the start of the test it was necessary to translate all excel files into 13 Tuesday 26 07 Wednesd ay 27 07 portuguese language and reinsert links and formulas During the process some formulas were not properly inserted into the new excel file analysis table Consequently the calculated amount of substrate to be fed into the fermenter for the test was wrong Together with the fact of significant difference in temperature between both pools decision to stop th
32. p with app 200 g inoculum and the values were recorded After a short homogenization process the fermenters have been connected to the measuring tubes The measuring tubes were fixed to the fermenter with a metal clip After the installation of the fermenters the system was filled up with nitrogen in order to certify the tight and approved The fermentation test was now ready to start ce a 1 d M N V fm NS LS h en uw a Image 35 Experiment monitoring Thursday Meeting with FPTI EMBRAPA and BOKU members to discuss new projects 11 21 07 The meeting started with an introduction by Mr Bley who explained the general objectives of the installation of the biodigestors in the Parana basin 3 region The manure management of the animal production is an urgent matter to be improved basically to minimize the environmental impact Biogas production is considered primarily as a valid method to tread those organic residues He also pointed out the existing political decision to support biogas as renewable energy source and explained that other Brazilian institutions potentially will adopt the biogas research laboratory according to the BOKU model Even other countries in Latin America show strong interest to the presented solution as for example Chile Mr Bley furthermore explained the PTI s idea to set up a SOP like list of standardized information on how to build up and to manage a high quality biogas resea
33. pted and took 1 5hours until the end of discussion Image 23 Presentation Start of volatile solids determination The dry matter was weighed By using the crucibles previously prepared during 5 hours at 550 C first the tare was weighed and then the dry matter of approximately 2kg The material was directed to the muffle as to slowly achieve a temperature of 550 C in 2 hours 250 C and in the next hour 550 C and remains 3 hours in this temperature Magnet stirrer and heating plate equipment End of temperature testing and organisation of a new heating system for the fermenters The temperature of the fermenters that were stable the previous day had a temperature of 40 C today which is the minimum possible temperature for this equipment Due to this reason it is not possible to use this system A new heating system was provided in which small heating systems connected to a thermostat will maintain the temperature at a required level End of volatile solids determination Wednesd Calculation demonstration volatile solids ay Based on the table developed at BOKU Laboratory 10 years ago the required calculations to 13 07 determine the dry matter and the solid volatiles were shown An additional table developed at FPTI laboratory was used as well to present the results Data analysis The criteria to evaluate statistically the results were shown to allow a decision whether a repetition of the test is necessary or not The results of th
34. rch laboratory This list shall function as a template to be distributed to other interested institutions Mr Passo Neto explained the different areas where the potential of biogas production in the regions is seen These are as follows Industrial area e poultry slaughter e Cassava manufactory e UPL unities of piglets production e Vinasse not relevant for the region Rural area e pig and cattle manure e Possibly poultry manure e Energy crops mais silage oats grass Urban area e domestic residuos e residuos of restaurants e PTI pilot project Later on the BOKU view was presented by Mrs Lyson The different research areas suggested by Prof Amon have been presented A Joint Advanced Research Program FPTI BOKU has been discussed extensively beforehand between Prof Amon and Mr Cicerlo Bley During the meeting on 21st of July the content has been adapted in the following way Suggestions for cooperation and further joint research projects 1 residual gas potential of digestate from existing biogas plants in Brazil animal manures winter summer comparison cattle swine and poultry Remarks The management of the poultry manure has no high priority as the treatment of solid manure is essentially resolved Following projects should priority to pig and cattle manure It would be an interesting task to conduct an analyze of the biogas potential for the winter months There is no internal heating system within the fermenter
35. re In the laboratory the material was tested at 37 5 C regarding its acclimatization until the beginning of the experiment Start of dry matter determination Before the dry matter and the solid volatiles were determined it was detected that the available crucibles were too small to determine the dry mass of a substrate with a high water level In order to prevent a waste of time we started testing the dry matter in two phases i e using 105 C beaker containers for the dry matter analysis The container was weighed and then an approximate portion of 130 gram were weighed and taken to the dryer It remained in the dryer until the weight of the substrate remained constant The result was achieved the following Monday On the other hand there was a necessity to get crucibles with adequate dimensions from a laboratory of the UNILA This material will be available next week Manual revision and adjustments 2 part see table 4 Week 2 Activities Monday Magnet stirrer and heating plate equipment installation temperature test 11 07 The 12 ordered apparatus arrived on Friday On Monday they were tested They were all connected to the network An expert supported this process as to ensure that the energy supply is not jeopardized by the required electric power system All apparatus were connected at the temperature in phase 2 and a simulation was performed by heating the fermenter filled with water within a larger container with water
36. rmometer does not possess a decimal place Our recommendation was to presently use a mercury thermometer since it allows a more accurate temperature indication as it is required nevertheless it is not a perfect solution A digital thermometer with one decimal place was ordered but it was not still available 1 2 Suggestions from BOKU side to optimize the FPTI laboratory Table 3 shows all suggestions from the BOKU in the time of the training in order to improve the laboratory work and to ensure optimum results of the biogas experiments Table 3 Previous situation of FPTI laboratory and proposed solutions Inoculum preparation Situation The inoculum gathered prior to the training cannot be used for the test Problems Suggestions 1 The inoculum was collected at the pre 1 The inoculum sample must be taken directly to fermenter from a biogas plant which has a high the main digester because in this place the bacteria level of organic material and thus a high activity is smaller than in pre fermenter microbial activity These characteristics are not intended for the inoculum since an excessive microbial activity disguises the fermentation result of the substrate to be tested 2 During the period the inoculum was kept in 2 The inoculum must be stored in a recipient with a the cabinet dryer it concentrated dry matter The small cover that is not too tight Thus the gas may container of the inoculum was stored and had
37. s analysis Recommendations from Ricardo Embrapa about analysis experience in Brazil were taken into account Two specific procedures were written depending on the type of material liquids or solids Installing a drop box in the laboratory Computer Explanation of how to use it to share data and results with BOKU Caroliny explains the idea to create a software at PTI to build a Database involving different biogas laboratories in Brazil and Latin America Possibility to discuss with BOKU about experiences in Europe Checking with Eliza list of equipment already ordered Suggestion to order more equipment such as specific laboratory tweezers laboratory spoons funnels of different sizes gardening scissors Control and monitoring the experiment Reading off daily gas production Collection of data and input into the excel file Monitoring room temperature and stirring fermenters Visit from an investment institution interested in Biogas research Climate control unit image 44 The goal is to heat the room approximate temperature control during the night and maintain it constant during the day Checking parameters to adjust an optimum 17 Freiday 05 08 Week 6 Monday 08 08 Tuesday 09 08 temperature Image 44 Climate control unit Get in touch with the oven and muffle manufacturer in order to get a gas collector connected to outside to avoid presence of toxic gases in the labor Possibility to order a new muffle with
38. s which consequently leads to a strong decrease of biogas production To conduct a calculation of investment costs for a heating system and to check the economic viability is strongly recommended Another problem occurs during the summer months The biogas production is considerably higher than the storage capacity Therefore there is a strong need to optimize the construction plan of the biogas plants Other needs to be mentioned are as follows e To make better use of the heat e To optimise the biogas quality e To optimize the fermentation conditions temperature frequency of feeding homogenization of the substrates 2 Determination of the biogas potential of urban residues food residues and rests of 12 grass cut Remarks The potential of biogas production of these kinds of materials has a strong priority in comparison to cofermentation from animal manure and energy crops This is because of the local and regional available substrates as well as due to the fact that FPTI currently sets up a pilot plant which will work with the mentioned raw materials A new research project is urgently needed to support the pilot project 3 Determination of the biogas potential from energy crops Remarks This research project would aim at giving an alternative to producers to make better user of the soil in the winter months and thus to rise the economic income of the producer Together the three projects should deliver sufficient data to set u
39. see point 1 not possible to control the temperature escalation of the fermenter Dry matter and volatile solids content analysis Situation There was no gas exhaust to the muffle and cabinet dryer The laboratory will change its location in October thus a high investment on the structure of the laboratory was not necessary Problem Suggestion 1 situation is not adequate for the laboratory 1 In any case the installation of a gas exhausts worker system Laboratory organization Situation The worker s concentration is often disturbed e g through unexpected visits unexpected work orders constant calls Problem Suggestions 1 It could cause a distraction during an analyze lecture The laboratory s work claims a high concentration level and continuity Interferences are not recommended 1 Any visit should be scheduled 2 The tasks assigned shall comply with a priority and it is necessary to draw the attention of their supervisors to the consequences that an assigned task in a certain moment may harm the analyses and the reliability of the laboratory 3 Phone calls need also comply with a priority and must not interfere with the course of the analysis 2 Introduction into fermentation laboratories second stage journal The introduction into the fermentation laboratory second stage takes the operational process under subtropical climate in Foz do Iguacu into consideration This activity was support
40. sure output weight Start monitoring the temperature in the laboratory Using thermometer provided with maximum and minimum to know how much degrees decrease during the night At the moment is winter in Brazil and the temperature decrease significantly Testing Dr ger equipment The one from PTI is borrowed from a professor Checking different options and testing with the gas test is found out is not calibrated The composition of test gas at laboratory is 70 CH and 3096 CO Suggestion to order a test gas a with a standard composition 5096 CH 40 CO 1096 N Whole Drager equipment Whole new Drager equipment is expected to come in September Friday Volatile solids analysis 29 07 Putting the samples from the muffle into the dessicator for one hour Measuring output weight and write it down in the table Checking if difference between replicates is lower than 2 so we can accept the method Results from VS analysis put into the excel file Mixture of Samples to obtain the amounts of substrate for the Batch test DM and VS analysis results from the substrates were obtained previously Testing magnet stirrers inside the fermenter filled in with inoculum Stirring system is integrated in the heater although is independent and is provided with a speed control At the minimum speed the rotation speed is not equal in every system so we decide to use just six working properly and stir alternately the four units Proposal to buy some kin
41. tion project plaque This project involves 34 small and middle livestock farmers each of those has a small biogas plant A total of 1072 cattle and 3082 pigs produce the organic material for the anaerobic digestion The expected annual production consists in 16 thousand m manure 267 thousand m biogas and 445 thousand kWh electrical energy All farmers are connected to one central power generator and send their own energy to this central This project comprises a total of 25 km ducts to transport the biogas We visited 2 farmers one pig and one cattle owner Both had very good experiences We were told that they invested in the animal installations but the biogas plant and biogas ducts were financed by the project Description of the biogas plant at the pig owner This property has an average of 700 farrows One biogas plant follows the Canadian model with a rectangular storage tank for waste that is covered by a gas collecting canvas image 14 and a secondary storage tank for depositing already fermented organic material image 15 The substrate to be fermented is pumped every third day to the fermenter A mixture of the substrate in the fermenter is made once a day by pumping during a period of approximately 2 hours The produced biogas is liberated from moisture and solid particles using purifiers installed in the same property image 16 Having concluded this purification the biogas is led by means of an underground conduit to an ele
42. well as weeding rests from the mill area From our point of view all items regarding the necessity to maintain a constant room temperature and the gas exhausts of the dryer and the muffle were clarified Mr Passo Neto is currently the contact person instead of Mr Trindade FPTI CEB Center of Biogas Study of FPTI Sealing liquid preparation and storage of inoculum from Embrapa The confined liquid used in the eudiometers was prepared in a limited portion with regards to the available reagents and according to the manual Storage of inoculum from Embrapa The colleague Mr Ricardo Steinmetz from EMBRAPA came to FPTI to participate in the training by cooperating mainly in the calibration of the eudiometers providing the inoculum and supporting the adjustments in the manual The inoculum he brought was stored at a temperature of 37 5 C Week schedule Tuesday Presentation to FPTI personal 12 07 Optimization of biogas production resulting from maize sorghum and rye under dry climatic conditions image 23 Mr Cicero Bley Mr Marcelo Alves de Souza and about 15 participants from FPTI and the Federal Technological University of Paran UTFPR a Brazilian company of agricultural research EMBRAPA Regional Development Agency of West Coast of Paran ADEOP incubated companies International Hydroinformatics Center CIH Center of Biogas Study CEB and Itaipu Consulting for renewable energies The presentation was very well acce
43. y Homogeneity Other characteristics colour grain size grain distribution odour gas development 2 2 Sample preparation Preparation Inclusion of the term sample to allow a better understanding Creation of the sample properties required for a The term sizing is not applicable in the region representative sample or for the fermentation therefore it has been excluded from the manual trial by means of separation size reduction sizing via screens and so on Cumulative sample This was the same problem as above Both terms See composite sample Cumulative sample and composite sample should be maintained in the manual as both terms may be found in the literature Inflow concentration In the Portuguese translation this term was changed to Concentracdo de entrada afluente instead Concentra o de influx 2 3 2 Storage at 18 28 C Do to the increasing of volume of frozen water Inclusion of the explicative note e g fiber broken this kind of storage is a physical way of pre to make the text easier to understand treatment 21 2 3 4 Storage under vacuum Comment Materials with a high amount of easily degradable organic components 4 2 Making of the inoculum Doubt about the term standardized inoculum 5 Batch experiments Batch experiments Feed material are incubated under mesophilic conditions 37 5 C 0 5 C 5 2 Start of the experiment The substrate
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