Solid Waste Management at Kalyani Cleantech

SOLID WASTE MANAGEMENT

Globally an estimated 2.8 billion people rely on septic tanks, latrines or other improved non-sewered sanitation technologies. There is lack of solutions to adequately manage fecal sludge, agriculture waste that collects in these technologies. This results in negative implications for public and environmental health & economic development. There is a need for decentralized fecal sludge treatment and other agro - waste treatment that can quickly deployed and affordably operated. Kalyani Cleantech is an exclusive licensed manufacturer of such biogenic refinery who can cater to the FSM sector.

ABOUT KCPL & BIOMASS CONTROLS

DECENTRALIZED SANITATION

NUTRIENT RECOVERY

PRODUCTS & APPLICATIONS

GREENHOUSE GAS REDUCTION

BIOCHAR REUSE APPLICATIONS

HOW DOES BIOGENIC REFINERY WORKS

BIOMASS CONTROLS - DATA MANAGEMENT SERVICES

1.GREENHOUSE GAS REDUCTION

We have partnered with Native Energy to develop a system that will separate dairy manure solids from raw dairy manure slurry, where the separated solids portion will be pyrolyzed to produce biochar. The goals of the project are to reduce greenhouse gases associated with farm resources (manures) and recover nutrients. We have a second project through the USDA National Institute of Food and Agriculture (NIFA) for pyrolysis of hog manure solids in lagoons. The proposed phase 1 program is to develop and validate the use of our farmscale biogenic refinery pyrolysis-combustion process to convert lagoon hog manure to value-added biochar.

2. DECENTRALIZED SANITATION

Biomass Controls manufactures an efficient biorefinery that cleanly processes high moisture biogenic resources while generating capital in the form of tipping fees, service contracts, thermal energy, electrical energy, water and biochar. The Biomass Controls sanitation innovation is the ability to add toilet resources to our bio-refinery and output products such as thermal energy and biochar. It is designed for communities of 10,000-50,000 people. The refinery is integrated into a transportable shipping container. It can reduce solids volume by over 90%. The thermal process output is a pathogen free product. The bio-refinery has a small footprint, can be operational in a few days, can run at temperatures from -40°C to 30°C, and processes 30,000 liters or one tonne of material each day. In over four years of field implementation and operational experience, the Biogenic Refinery accumulated over 20,000 hours of data. The collected data has resulted in process optimization and patented technologies that enable reliable and efficient treatment performance.

3.NUTRIENT RECOVERY

Biomass Controls is working with Dr. Thomas Trabolds of Rochester Institute of Technology’s Golisano Institute for Sustainability. The research is for the valorization of organic waste materials, with a focus on food waste. Recent research has focused on applying thermochemical processes of gasification and pyrolysis, whereby food waste is processed between 500C – 800C under reduced oxygen conditions to yield hydrogen-rich syngas and a solid carbon material called “biochar”, suitable as a sustainable fertilizer or adsorption medium. The recently published book Sustainable Food Waste-to-Energy Systems, co-edited by Trabold and Dr. Callie Babbitt, presents various food waste conversion technologies, as well as environmental, economic and policy analyses of these systems.

4.About KCPL & Biomass Controls

• KCPL and Biomass Controls together have formed a manufacturing agreement to work closely to cater FSM Sector. Last year both the parties have joined their hands.
• KCPL is having manufacturing expertise to built state of art. Biogenic Thermal Refineries required to enter the FSM Sector.
• We provides decentralized rapid nutrient recovery and treatment for green resources including, manure, textiles, food and excreta.
• Biomass Controls patents are based on protecting the environment and returning nutrients to the soil.
• Biogenic Refinery provides thermochemical treatment of high moisture materials such as manures, human excreta, agriculture residues and food waste. Their services provide Design, Technology Adoption Support, and Impact Measurement

5.PRODUCT & APPLICATIONS

Globally, an estimated 2.8 billion people rely on septic tanks, latrines or other improved non-sewered sanitation technologies. There is a lack of solutions to adequately manage fecal sludge that collects in these technologies. This results in negative implications for public and environmental health, and economic development. There is a need for decentralized fecal sludge treatment that can be quickly deployed and affordably operated.

Transforming Fecal Waste

The Biogenic Refinery is a thermal treatment solution using patented technology that provides treatment products such as pathogen free biochar, heat and electricity. Thousands of hours of operational data have been collected from biogenic refineries operating on three continents, in temperatures as low as -20˚C. The Biogenic Refinery is transportable, designed to operate off-grid and can handle input products with moisture contents as high as 35%.

Biogenic Refinery Benefits

•RAPID AVAILABILITY, SCALABILITY small footprint and modular design allow for fast deployment. Distributed and cascaded systems deliver high availability and scalability from 10 to 35,000 people.
• EFFECTIVE TREATMENT Pathogens are inactivated within 24 hours by the pyrolysis-combustion process, and a volume reduction of 90% is achieved on a dry basis.
• VALUABLE TREATMENT PRODUCTS Biochar can be used as a soil amendment, for filtration, cooking or heating. Thermal energy can be used for pasteurization and drying of the feedstock and for electricity generation.
• REMOTE PERFORMANCE MONITORING The kelv˚n software platform offers real-time reporting and alerts to operators and supervisors, allows for remote monitoring and provides user interaction through a mobile or web interface.

Producing Biochar from Human Excreta

What is biochar? Biochar is the solid product of pyrolysis, which occurs when biomass is brought to high temperatures with limited oxygen. Biochar’s properties present opportunities for improving soil health, removing contaminants and recovering nutrients as well as providing a mechanism for carbon capture.

Biochar Properties

• Biochar is extremely porous; it has a deceptively high surface area, making it a powerful adsorbing matrix with many potential applications.
• Biochar has a very high adsorption capacity, capturing contaminants and volatile compounds brought into contact with it.
• Many heavy metals, minerals and other non-volatile components in biosolids are retained as solids and immobilized within the biochar structure.
• Biochar Production

Pyrolysis is a thermal process that occurs at high temperatures in the absence of oxygen, unlike combustion. The heat generated during pyrolysis of human excreta provides complete pathogen-kill. Pyrolysis results in significant volume reduction and produces carbon-rich biochar. The time and temperature of pyrolysis and chemical makeup of the biomass greatly influence biochar quality. Biochars produced from nutrient-rich materials such as faecal sludge contain plant-available nutrients such as phosphorus and potassium.

6.BIOCHAR APPLICATIONS

• SOIL AMENDMENT Biochar is an intrinsic component of soil organic matter, found to make up as much as 30% of the organic matter in some of the most fertile soils on Earth. Biochar addition to agricultural soil as a fertilizer additive brings an improvement to the soil’s water retention ability, nutrient retention, and nutrient uptake. Certain plant-essential nutrients like phosphorus and potassium remain in biochar made from nutrient-rich biomass.
• COMPOST ADDITIVE Biochar additives have been shown through many studies to improve performance and reduce greenhouse gas emissions during the composting process. Biochar addition to compost feedstock has been shown to increase microbial activity and accelerate decomposition and humification.
• CARBON SEQUESTRATION The majority of the carbon from the source biomass is retained in biochar in a form not easily degraded by microorganisms, therefore remaining in the soil for hundreds of years. Biochar application to soil is an effective mechanism for carbon-capture and climate change mitigation, preventing carbon from entering the atmosphere as a gaseous emission.
• HEAVY METAL IMMOBILIZATION Heavy metals from the source biomass are incorporated into the biochar structure, immobilizing the metals and buffering their presence in the environment.
• ODOR CONTROL Biochar provides odor control through the adsorption of volatile compounds. Biochar derived from human excreta has been shown to successfully adsorb airborne molecules responsible for fecal malodor.
• STORMWATER REMEDIATION Biochar can act as a water filtration medium, effectively removing pollutants from stormwater. The inclusion of biochar media in stormwater remediation solutions improves organic contaminant removal, nutrient removal as well as heavy metal immobilisation.
• CONSTRUCTION MATERIAL ADDITIVES Biochar is a suitable filler to reduce the environmental impact of concrete while improving thermal and acoustic properties. It is also an effective additive to bitumen binder to increase resistance to pavement engineering challenges.

7.HOW DOES BIOGENIC REFINERY WORKS

1. Feedstock is continuously fed by an auger into the pyrolysis pot where it is exposed to high temperature pyrolysis, rapidly converting the feedstock to biochar
2. Biochar is continuously removed from the pyrolysis pot by another auger to the biochar box, where it is available for easy removal
3. Volatiles liberated from the feedstock are thermochemically destroyed by the catalytic converter
4. Hot gases are thermally treated by a heat exchanger, converting thermal energy to use in drying of dewatered feedstocks or space heating
5. Low odor, low emissions exhaust gas is released from the stack
6. The process runs at steady-state on less than 1 kW of electric power

Innovation and Benefits

• Adaptable to treat almost any volume of organic matter (including high-moisture content matter) using small scale modular set-up
• Instantaneous pathogen kill in all solids using unique pyrolysis-combustion eliminating biological hazards on site
• 90% volume reduction of feedstock converted into useful, inert biochar.
• Real time remote monitoring and control of the units with the Biomass Controls Kelvin app
• Small footprint, little noise, and emit little to no odor or emissions thanks to sophisticated control technology

Prototype combined heat and power (CHP) system to generate electrical energy from output thermal energy, for off-grid operation

BIOGENIC REFINERY TECHNICAL DESCRIPTION

The Biomass Controls Biogenic Refinery (BR) is a small-scale processor, capable of refining any biogenic matter into inert carbon with significant volume reduction, carbon sequestration in the form of biochar, and controlled emissions. The BR uses a continuous, efficient pyrolysis-combustion system to instantaneously inactivate all pathogens while producing thermal energy useful for drying and value added biochar with a volume reduction of approximately 90% over original feedstock. Each BR is capable of processing up to 960 kg (assuming 24 hours of runtime) of organic waste per day on a dry basis, converting to up to 173 kg of biochar.

The Biogenic Refinery occupies a small footprint, but is packed with emerging technologies that provide cost-effective process efficiency, greenhouse gas (GHG) emissions reductions, economic, and environmental benefits. Biogenic Refinery Benefits

• RAPID AVAILABILITY, SCALABILITY A small footprint and modular design allow for fast deployment. Distributed and cascaded systems deliver high availability and scalability from 10 to 35,000 people.
• EFFECTIVE TREATMENT Pathogens are inactivated within 24 hours by the pyrolysis-combustion process, and a volume reduction of 90% is achieved on a dry basis.
• VALUABLE TREATMENT PRODUCTS Biochar can be used as a soil amendment, for filtration, cooking or heating. Thermal energy can be used for pasteurization and drying of the feedstock and for electricity generation.
• REMOTE PERFORMANCE MONITORING The kelv˚n software platform offers real-time reporting and alerts to operators and supervisors, allows for remote monitoring and provides user interaction through a mobile or web interface.

8. BIOMASS CONTROLS – DATA MANAGEMENT SERVICES

OUR COMPLETED PROJECTS

Biomass Controls has executed 3 Projects in India 2 Projects in Warangal – Andhra Pradesh

KALYANI CLEANTECH

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