Anaerobic Digestion Technology Information Brochure

THE BEST PARTNER FOR
ORGANIC WASTE TRANSFORMATION
TECHNOLOGY APPLIED TO THE ENVIRONMENT

A waste is an evidence of an unoptimized process. In ROS ROCA we believe that a waste is also an opportunity to develop a process
that uses it as a resource to produce a valuable end-product or event energy.
We treat organic wastes or process water, and allow nutrients recovery to the natural cycle,reducing the environmental impact of other
ways of elimination.
Ros Roca Ingeniería del Medioambiente SL was born in 1994 as a Business Unit from Ros Roca SA, focused to Municipal Solid Waste
transfer and treatment. This activity is enlarged from 1998 with the development of an own in-vessel composting system. We have
built more than twenty composting units from 10.000 to 95.000 t/y.
New century marked also a new horizon with the incorporation of an Anaerobic Digestion system for Organic Waste treatment and turn
to energy. Actually we have yet fiveteen facilities working and four new contracts under execution.
After this longtime experience, Ros Roca became one of the leading companies in its sector. From our headquarters in Tàrrega
(Spain) or our office in Östfildern (Germany) we design, plan, and turnkey execute projects of facilities for organic wastes treatment
and wastewater.
Our expertise allows us to follow up one of our main targets: “To fit customer’s needs”. That means we develop flexible solutions to
adapt basic concepts to a wide range of wastes and particular conditions of our customers
Flexibility in waste treatment:
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Biowaste (Organic fraction from MSW)
Municipal solid waste.
Food Industries Organic waste.
Agricultural wastes (including Manure).
Slaughterhouse wastes.
Sewage sludge.
Green waste from gardening and pruning.
Flexibility in services:
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THE BEST PARTNER FOR
ORGANIC WASTE TRANSFORMATION
Research and testing in our own installations or in some partner laboratories.
Planning and basic procedures advisement.
Engineering, construction and start-up.
Long term operation supervision and advisement.
The Quality management system is applied to the design, production, distribution and sales of urban and industrial cleaning and sewerage systems.
Specifications subject to modification without prior notice.
The illustrations may not correspond to standard versions of the units.

THE BEST PARTNER FOR
ORGANIC WASTE TRANSFORMATION
MBT CONCEpT dEVElOpMENT
The use of Mechanical devices at industrial scale to prepare waste streams
for further Biological processes is the key for the successful operation of
most of the units, specially those that works with a very heterogeneous
material like MSW.
From simple steps like size reduction or magnetic separation to delicate
ones as automatic infrared separation devices for plastics, the manipulation
of MSW streams to separate organics and recover the most of valuable
ThE ChOOSE FOR ThE BIOlOGICAl:
ANAEROBIC OR AEROBIC
If we look at one of the most important legislation, the Landfill directive, we see the
most ambitious objective : Mass reduction for disposal of organic material and reduction
of landfill emissions (gas, leakage water)
Anaerobic Digestion systems are especially interesting in the context of the twin objectives
of moving MSW away from landfill, and in seeking to develop supplies of renewable
energy. MSW has to move away from landfill-based systems, and not before time.
These considerations, alongside the fact that a range of other biowastes apart of Organic
fraction from MSW are likely to be available, makes AD a very interesting technological
option for waste management. AD is a long experienced and well proven
technology to treat organic waste streams.
Anaerobic Digestion permits to transform highly efficiently agricultural or organic industrial
by-products into renewable energy. It presents a synergistic approach with
the co-treatment of organic complementary wastes that sometimes are very difficult to
treat by separate. It also allows to address a different number of issues: energy production,
rural economic development, pathogen and odour reduction, income diversification…etc,
and changes the perception for waste as a resource. AD is a contribution to
substitute fossil energy sources and to reduce CO2- emissions
Ros Roca uses a wet AD system, flexible technology for different types of organic
material, energy self-sufficient with a high surplus of electric and thermal energy and
with an end product high quality, due to the efficient pre-treatment to remove all no
fermentable materials from main stream.
elements for recycling is been one of our main worries in the last decade.
New packaging materials and new legal framework, like the Landfill directive
converts this purpose in a difficult challenge that force our engineers to
be permanently updated of new machinery application.
The result is an intelligent combination of equipment, with different adaptations
depending to the final destination for the end products: Recycling,
Energy recovery or Landfilling.

pRE-TREATMENT
In general, the nature of pre-treatment will depend upon
the quality of separation of the feedstock which is anticipated.
Just as with composting, accurately segregated
fractions make materials handling much easier. Even
Source Separated OFMSW usually requires further separation
to remove wrongly sorted materials such as plastics,
metals and oversized components.
Separation can be carried out under wet and/or dry conditions,
depending of the nature non-fermentable particles.
After initial separation of materials, a process of pulping
and size reduction is used to create a more homogenous
suspension which will aid fermentation and facilitate
processing, by increasing degradation yields and accelerating
the digestion process. For this purpose, usually
process water must be added to the feedstock at the wet
pretreatment stage to dilute the waste (organic materials
range from 10-30% TS).
Once this suspension is ready is discharged to the grit
trap/sand separation system to extract all the small nonfermentable
particles, such plastics, stones, sand,…before
feeding the fermenters.
SANITATION STEp
Anaerobic digestion is a process that reduces pathogens, as evidenced by its use in the stabilization of wastewater sludges.
Nevertheless a specific pasteurisation step can be added to the process if the direct use of digested material is wanted. This stage maintains the feedstock
at 70ºC for one hour prior to feeding to the digester. This allows the pathogen reduction requirement to be met.

THE BEST PARTNER FOR
ORGANIC WASTE TRANSFORMATION
dIGESTION STAGE
Simple but reliable. Only the anaerobic fermentation matter, non-fermentable
particles free, are feed to the digester.
This is a vertical reactor, cylindrical shape, with a dome on top to recover
all the biogas produced. The suspension is preheated at 37ºC before feeding,
and inside the Digester is continuously moved injecting a part of bio-
AFTER dIGESTION. SOlId-lIquId SEpARATION?
Following digestion, the digested solids would require dewatering before being
sent to the final curing location. This dewatering would occur by means
of rotary centrifuges. A polymer solution would be added prior to the presses
to flocculate the solids and facilitate solids separation.
Most of the water removed at this stage would be recycled to the pulping
and wet separation stage of the front-end processing. The remainder would
be wastewater, which may require some treatment for the reduction of nitrogen,
phosphorus and suspended solids.
gas produced by means of stainless steel
pipes from center top of the reactor. No
moving parts inside, so no high maintenance
cost.
Simplicity in concept, guaranties in the
execution. We choose steel tanks and
follow the most restrictive regulations for
tank welding: The API rules. Because we
want the best transformation efficiency
but also to minimize methane loses, and
eliminate safety risks.
Once the tank is API650 approved, we
insulate it to reduce thermal loses and
energy consumption
Security is our obsession: working at low
pressure system, double security devices,
(overpressure valves and underpressure), flare and flame arresters,…all
following the most restrictive ATEX regulations, to deliver a reliable installation
to trasmit trust to our customers.
Improved process control and monitoring is also another key for best efficiency.
A PCS7 system and a specific SCADA application will drive the
process to get the best results.
In some specific units we use directly the digested suspension as a liquid
fertiliser. In this case, no wastewater is generated.
The wastewater stream is primarily a function of the incoming feedstock,
since the bacterial process is essentially the same, the main difference being
the extent of carbon conversion.
Although we pump more water in our process, most of this is recycled process
water so the net amount of wastewater produced is not necessarily
significantly higher than for other technologies.

ON-SITE TREATMENT OF BIOGAS
The quality of the gas (ie., levels of contaminants) may vary slightly for
different feedstocks. Biogas from the digester will have contaminants such
as hydrogen sulphide and moisture, which may need to be removed before
use, because both are major causes of corrosion in biogas utilization equipment.
The biogas treatment and the extent required is largely dependent
on the end use of the gas.
If the biogas were to be used for onsite co-generation, an Otto type engine
would be used. These co-generators are designed for digester and landfill
FuRhTER STABIlISATION.
COMBINEd TEChNOlOGIES
The dewatered digested sludge undergo further treatment in an enclosed
final composting section during several weeks to achieve maximum
stabilisation degree.
Depending on finally quality wanted, this composting system can be
static in-vessel systems or dynamic semi-enclosed. In any case, forced
aeration with centrifugal fans is the key to eliminate all methane
and hydrogen sulphide traces, assure the aerobic conditions and
allow curing process conditions. All the exhaust air is collected and
conduced to a specific treatment.
Water contents control is also another very important factor, so the
system is equipped with watering lines with leakage recover and reuse
system. No excess water is produced.
PLC monitored system will work in this three control parameters: oxygen
level, humidity control and temperature level.
All this will warranty the quality of final composted organics, the repeatability
and reliability of the system.
gas, and are less sensitive to moisture and sulfides.
Generating electricity and process heat on site would eliminate the need to
purchase electricity and heat for the plant, and then could sell the surplus
of electricity to the electrical grid. Depending on the feedstock nature this
electricity surplus can be even larger than 60%.
If biogas want’s to be used off-site, as a biofuel, additional upgrading systems
can be used. Ros Roca has a specific technology for biogas upgrading
by high pressure water scrubbing.

THE BEST PARTNER FOR
ORGANIC WASTE TRANSFORMATION
OUR REFERENCES
Anaerobic Digestion Unit of KIELEN (Luxembourg)
Promoter: Naturgas Kielen
Address: Kooperative Naturgas Kielen, Zëntestall. 8280 Luxemburgo
Capacity: 48.400 t/year
Input: Organic waste, Energy crop, Cow manure and coe haeces.
Status: Under construction.
AD Facility of SÃO MARTINHO DO PORTO (Portugal)
Promoter: TREVOESTE
Capacity: 55.000 t/year
Input: Pig manure
Status: Under construction.
AD Facility of EL CAMPELLO-ALICANTE (Spain)
Promoter: Consorcio de residuos de la zona XV de Alicante.
Address: Planta de tratamiento de Las Marinas. CN-332, PK.
125.9, El Campello, Alicante
Capacity: 52.000 t/year
Input: Organic from MSW after mechannical pretreatment
Status: Under construction.
AD Facility of VOGHERA (Italy)
Promoter: ASM Voghera,SPA. Via Pozzoli, 2. 27058 VOGHERA (ITALIA)
Address: Impianto di Depurazione e Tratamento FORSU. Via del Postiglione.
27058 Voghera (Italia)
Capacity: 27.000 t/year
Input: Biowaste and Sewage Sludge
Status: Working from 2008

AD Facility of LOMMEL (Belgium)
Promoter: BIO-ENERGY
Address: Industrialpark Maatheide 76, 3920 Lommel, (Belgien)
Capacity: 150.000 t/year
Input: Potato and potato processing wastes
Status: Working from 2008
AD Facility of KROSNO (Poland)
Address: Zakład Unieszkodliwiania Odpadów (ZUO), KROSNO POLAND
Capacity: 10.000 t/year
Input: Organic from MSW after mechannical pretreatment
Status: Working from 2006
Anaerobic Digestion unit of WIEN (Austria)
Promoter: IBS Biogas WienJohann Petrak GasseA-1110 Wien (Österreich)
Address: Wien, Austria
Capacity: 17.000 t/year
Input: Biowaste and food industry wastes
Status: Working from 2008
AD Facility of SALTO DEL NEGRO (Spain)
Promoter: Dirección Gral. Medio Ambiente de Canarias
Address: Gran Canaria, Spain.
Capacity: 60.000 t/year
Input: Organic from MSW after mechannical pretreatment
Status: Start up pending
AD Facility of VALHALA (Stonia)
Address: Saaremaa Animal Waste Management Project,
Jööri village-Valjala SAAREMAA, Stonia
Capacity: 40.000 t/year
Input: Pig manure and Sewage Sludge
Status: Working from 2005

AD Facility of TUDELA (Spain)
Promoter: Mancomunidad de residuos Sólidos de la Ribera .
Address: Vertedero de “El Culebrete” Crta. NA-160 Tudela a Fitero Km 13
Tudela (Navarra) Tel: +34 948 38 60 68
Capacity: 28.000 t/year
Input: Organic from MSW after mechanical pretreatment
Status: Working from 2006
Anaerobic Digestion unit of ECOPARC DEL MEDITERRANI (Spain)
Promoter: Entitat Metropolitana de Medi Ambient.
Address: Avinguda Eduard Maristany s/n, 08930 Sant Adrià del Besòs,
Barcelona, España
Capacity: 90.000 t/year
Input: Organic from MSW after mechanical pretreatment
Status: Working from 2006
AD Facility of JAEN (Spain)
Promoter: Junta de Andalucía, EGMASA,S.A.
Address: Ctra. Fuerte del Rey Km 5-6. Centro de Eliminación de Residuos
de Sierra-Sur. JAÉN (España)
Capacity: 20.000 t/year
Input: Organic from MSW after mechanical pretreatment
Status: Start up pending
AD Facility of DEISSLINGEN (Germany)
Address: BRS Bioenergie GmbH. Herrn Wölfle, Schopfelen 3,
78652 Deißlingen (GERMANY)
Capacity: 24.000 t/year
Input: Biowaste & sewage sludge
Status: Working from 2005
AD Facility of WOLKENSCHWAND (Germany)
Address: Franz Högl Kompostierbetrieb e.K. Dietrichsdorf 5
D – 84106 Volkenschwand
Capacity: 75.000 t/year
Input: Biowaste, food industry organic waste
Status: Working from 2005

Anaerobic Digestion unit of GESCHER (Germany)
Address: Entsorgungsgesellschaft Westmünsterland mbH
Baustelle OSMO – Anlagenbau GmbH & Co. KG
Estern 41. 48712 Gescher
Capacity: 17.000 t/year
Input: Biowaste and sewage Sludge
Status: Working from 2005
AD Facility of VASTERAS (Sweden)
Promoter: Svensk Växtkraft AB
Address: Nyängsleden Norra Gryta, SE-721 87. VÄSTERÅS, SWEDEN
Capacity: 23.000 t/year
Input: Biowaste, Energy crops (Ley) and Sewage Sludge
Status: Working from 2005
AD Facility of ZONZAMAS (Spain)
Promoter: Gobierno de Canarias - Cabildo de Lanzarote
Address: Complejo ambiental de Zonzamas. Crta de San Bartolomé a
Tahíche km 4. TEGUISE (LANZAROTE).
Capacity: 36.000 t/year
Input: Organic from MSW after mechannical pretreatment
Status: Working from 2008
AD Facility of PALMA DE MALLORCA (Spain)
Promoter: TIRME,S.A.
Address: Parc de Tecnologies Ambientals de Mallorca. Ctra. de Sóller, km 8,2.
Camí de Sa Fita. s/n. 07120 Marratxí (Palma Mallorca)
Capacity: 32.500 t/year
Input: Biowaste and food&kitchen waste
Status: Working from 2003
Anaerobic Digestion unit of AVILA (Spain)
Promoter: Junta de Castilla-León
Address: Centro de Tratamiento de Residuos de la Sierra de Gredos. Crta.
AV500 Km15,1 (URRACA-MIGUEL). 05195 ÁVILA (ESPAÑA)
Capacity: 36.000 t/year
Input: Organic from MSW after mechannical pretreatment
Status: Working from 2003

Ros Roca Ingeniería del Medio Ambiente, S. L. (I.M.A)
HEADQUARTERS
Avda Cervera s/n
25300 TÀRREGA (Lleida)
Tel: +34 973 508 100
Fax: +34 973 508 134
e-mail: ima@rosroca.com
NIEDERLASSUNG DEUTSCHLAND
Felix-Wankel-Str. 17
D-73760 Ostfildern-Nellingen
Tel. +49 711 310 599 70
Fax +49 711 310 599 79
e-mail: info@rosroca.de
TECHNOLOGY APPLIED TO THE ENVIRONMENT
www.integrum.es D.L.: L-549-2008