San Francisco Biofuel Program: Brown Grease to Biodiesel Demonstration (Project Report)
Municipal wastewater treatment facilities have typically been limited to the role of accepting wastewater, treating it to required levels, and disposing of its treatment residuals. However, a new view is emerging which includes wastewater treatment facilities as regional resource recovery centers. This view is a direct result of increasingly stringent regulations, concerns over energy use, carbon footprint, and worldwide depletion of fossil fuel resources. Resources in wastewater include chemical and thermal energy, as well as nutrients, and water. A waste stream such as residual grease, which concentrates in the drainage from restaurants (referred to as Trap Waste), is a good example of a resource with an energy content that can be recovered for beneficial reuse. If left in wastewater, grease accumulates inside of the wastewater collection system and can lead to increased corrosion and pipe blockages that can cause wastewater overflows. Also, grease in wastewater that arrives at the treatment facility can impair the operation of preliminary treatment equipment and is only partly removed in the primary treatment process. In addition, residual grease increases the demand in treatment materials such as oxygen in the secondary treatment process. When disposed of in landfills, grease is likely to undergo anaerobic decay prior to landfill capping, resulting in the atmospheric release of methane, a greenhouse gas (GHG). This research project was therefore conceptualized and implemented by the San Francisco Public Utilities Commission (SFPUC) to test the feasibility of energy recovery from Trap Waste in the form of Biodiesel or Methane gas. The research goals are given below: To validate technology performance; To determine the costs and benefits [including economic, socioeconomic, and GHG emissions reduction] associated with co-locating this type of operation at a municipal wastewater treatment plant (WWTP); To develop a business case or model for replication of the program by other municipal agencies (as applicable). In order to accomplish the goals of the project, the following steps were performed: 1. Operation of a demonstration facility designed to receive 10,000 to 12,000 gallons of raw Trap Waste each day from private Trap Waste hauling companies. The demonstration facility was designed and built by Pacific Biodiesel Technologies (PBTech). The demonstration facility would also recover 300 gallons of Brown Grease per day from the raw Trap Waste. The recovered Brown Grease was expected to contain no more than 2% Moisture, Insolubles, and Unsaponifiables (MIU) combined. 2. Co-digestion of the side streams (generated during the recovery of 300 gallons of Brown Grease from the raw Trap Waste) with wastewater sludge in the WWTP's anaerobic digesters. The effects of the side streams on anaerobic digestion were quantified by comparison with baseline data. 3. Production of 240 gallons per day of ASTM D6751-S15 grade Biodiesel fuel via a Biodiesel conversion demonstration facility, with the use of recovered Brown Grease as a feedstock. The demonstration facility was designed and built by Blackgold Biofuels (BGB). Side streams from this process were also co-digested with wastewater sludge. Bench-scale anaerobic digestion testing was conducted on side streams from both demonstration facilities to determine potential toxicity and/or changes in biogas production in the WWTP anaerobic digester. While there is a lot of theoretical data available on the lab-scale production of Biodiesel from grease Trap Waste, this full-scale demonstration project was one of the first of its kind in the United States. The project's environmental impacts were expected to include: Reduction of greenhouse gas emissions by prevention of the release of methane at landfills. Although the combustion product of Biodiesel and Methane gas produced in the Anaerobic digester, Carbon Dioxide, is also a greenhouse gas; it is 20 times weaker for the same amount (per mole) released, making its discharge preferable to that of Methane. The use of Biodiesel in place of fossil-fuel derived Diesel was expected to reduce net Carbon Dioxide, Ash Particulate, Sulfate, Silicate, and Soot emissions, thereby improving air quality.