Overview
A 50 t/d food waste plant using the full route of hydraulic pulping + three-phase oil extraction + mesophilic anaerobic digestion + biogas CHP. Waste goes in, and three things come out: sellable crude oil/grease, on-site power and heat, and treated water and emissions that meet discharge standards.
Design basis & feed conditions
The following are typical design values for a 50 t/d project. Before detailed design, we recommend continuous sampling over 3–5 days to test moisture, oil content and impurity rate, and to reconfirm equipment sizes accordingly.
Feed conditions
FEEDSTOCK| Treatment capacity | 50 t/d | 16,500 t/yr (330 days) |
| Feed source | Hotels, restaurants, canteens of institutions and schools | Mostly food waste (swill) |
| Moisture content | 75–80% | Design value 77% |
| Oil content | 3–4% | Design value 3.5% |
| Impurity rate | 3–5% | Plastic, utensils, glass, metal |
| Collection mode | Enclosed transfer truck | 5-t trucks, ~10 trips/day |
| Receiving hours | 6:00–18:00 | Peak 6 t/h |
Key design parameters
KEY PARAMETERS| Pulping concentration | 10–12% | High-pressure combined hydraulic pulping |
| Grit after removal | ≤0.5% | Protects the centrifuge drum |
| Oil-extraction heating temp | 70–80℃ | Demulsification in constant-temp tank |
| Three-phase capacity | 10–12 m³/h | 2 units, one duty one standby |
| Hydrolysis/acidification HRT | ~4 days | 250 m³ |
| Digestion temp / HRT | 35±2℃ / 22 days | 2×1000 m³ mesophilic |
| Volumetric load | 4.0 kgCOD/(m³·d) | Biogas 0.40 m³/kgCOD |
| Odor air volume | 25,000 m³/h | Scrubbing + biofilter |
| Applicable standards | CJJ 184-2012 Technical Code for Food Waste Treatment; GB 14554-93 Emission Standard for Odor Pollutants, Grade II | |
Process flow
Implemented exactly per the flow diagram you provided, in six stages. Blue marks key equipment and green marks outputs. Each stage notes the corresponding design parameters and material routing.
Receiving & pulping
MECHANICAL PRE-TREATMENTmechanical shearing + hydraulic scouring▸Raw-slurry buffer tank
homogenizing, tempering, anti-sedimentation
Feed 50 t/d, peak 6 t/h; slurry concentration 10–12%; inorganic impurities are separated and removed here.
Grit removal
SAND REMOVALUnderflow fine grit → screw press dewaterer → cake removed off-site; filtrate returns to the buffer tank. Grit after removal ≤0.5%, protecting the downstream centrifuge.
Heating & three-phase oil extraction
HEATING & 3-PHASE SEPARATION70–80℃, demulsification▸Three-phase horizontal disc centrifuge
Separated into three streams: crude oil/grease → insulated oil tank → sold; high-purity organic slurry → hydrolysis/acidification; fine bottom residue → returns to buffer tank for re-pulping.
Hydrolysis/acidification & mesophilic digestion
HYDROLYSIS & ANAEROBIC DIGESTION250m³, HRT≈4d▸Mesophilic anaerobic digester
2×1000m³, 35±2℃, HRT≈22d▸Biogas collection▸Gas-water separator
High-purity organic slurry 55 m³/d goes to digestion at a volumetric load of 4.0 kgCOD/(m³·d), yielding biogas 3,000 m³/d (CH₄≥60%); digestate 52 m³/d is removed for land application or discharge.
Biogas upgrading & utilization
BIOGAS UPGRADINGH₂S≤20ppm▸Double-membrane gas holder
1500m³ constant pressure▸Biogas distribution valve group
In two streams: biogas hot-water boiler 1.4MW → hot-water loop → digester and heating-tank insulation; biogas generator set 250kW → plant electrical system, self-generated for self-use, waste heat recovered for digestion heating.
Odor collection & treatment
ODOR COLLECTION & TREATMENTacid + alkali wash▸Biofilter
600m³ media▸15m stack, meeting discharge standards
Odor air volume 25,000 m³/h; meets Grade II of GB 14554-93 Emission Standard for Odor Pollutants.
Mass balance
50 t of waste + 15 t of make-up water, outputs are grease, biogas, impurities, grit residue and digestate. This table drives all downstream equipment sizes and revenue calculations.
Daily mass balance (design)
DAILY MASS BALANCE| Direction | Material | Amount | Unit | Routing / note |
|---|---|---|---|---|
| In | Food waste | 50.0 | t/d | Enclosed trucks delivered, weighed on site |
| Process make-up & wash water | 15.0 | m³/d | Pulping make-up, equipment and floor washing | |
| Out | Crude oil/grease | 1.8 | t/d | Insulated oil tank → for sale (moisture ≤3%) |
| Biogas | 3,000 | m³/d | After desulfurization → 6,000 kWh power / boiler heat | |
| Inorganic impurities | 2.0 | t/d | Pulper heavy-matter outlet → off-site incineration/landfill | |
| Dewatered grit residue | 2.0 | t/d | Cyclone grit removal → screw press dewatering (moisture ≤60%) | |
| Digestate | 52 | m³/d | Digestion effluent → land application or discharge | |
| Loss (evaporation, carry-over) | ~5 | t/d | Carried by odor exhaust and biogas |
Key equipment photos
Photos of the 8 core units in this plan; the models and list item numbers can be matched one-to-one with the equipment list that follows. Click an image to view the original.
Enclosed receiving hopperList 01 · PZS flat hopperEnclosed discharge + leachate collection, with negative-pressure extraction; no odor escape during discharge
High-pressure hydraulic pulperList 02 · ZSG pulping & sorting machineMechanical shearing + hydraulic scouring; outlet concentration stable at 10–12%
Raw-slurry buffer tank agitatorList 04 · ZFJ tank agitatorFlow mixing to prevent stratification, sedimentation and caking, ensuring uniform feed concentration
Shaftless screw conveyorList 06 · FSSB screw conveyorContinuously removes plastic, utensils and other inorganic impurities; no central shaft, no wrapping
High-concentration cyclone grit removerList 08 · ZCSG cyclone desanderCentrifugal grit removal: cleaned slurry overflows, grit discharges below, protecting the downstream centrifuge
Screw press dewatererList 09 · ZNJ screw pressGrit pressed to below 60% moisture, reducing off-site volume and disposal cost
Three-phase horizontal disc centrifugeList 12 · SXF three-phase separatorOil, water and residue separated in one pass; oil recovery ≥90%; grease goes straight to the tank
Scrubber / bio-deodorizationList 29 · FYCCXL negative-pressure odor systemCovered collection over tanks; acid + alkali wash + biofilter treatment before compliant discharge
Equipment list & quotation
Totaling 39 items in five systems. Unit prices are ex-works incl. 13% VAT (excl. freight, civil works and external electrical). Equipment subtotal RMB 9,506,000.
I. Receiving & pulping system
MECHANICAL PRE-TREATMENT| No. | Equipment | Model / spec | Qty | Unit | Unit price (10k RMB) | Amount (10k RMB) | Notes |
|---|---|---|---|---|---|---|---|
| 1 | Enclosed receiving hopper | V=10m³, hydraulic lid, leachate drainage | 2 | pc | 7.80 | 15.60 | Including grid and screw discharge |
| 2 | High-pressure hydraulic pulper | ZSGJ-5, mechanical shearing + hydraulic scouring | 2 | pc | 37.80 | 75.60 | 5 t/h each, one duty one standby |
| 3 | Pulping outlet screw pump | ZJB-11, Q=20m³/h | 2 | pc | 1.50 | 3.00 | One duty, one standby |
| 4 | Raw-slurry buffer tank agitator | QJB-4, 4kW | 4 | pc | 2.80 | 11.20 | Anti-sedimentation/stratification |
| 5 | Slurry feed pump | ZJB-11, VFD | 2 | pc | 1.80 | 3.60 | To cyclone grit removal |
| 6 | Shaftless screw conveyor | Ø400×8000 | 2 | pc | 4.80 | 9.60 | Removes inorganic impurities |
| 7 | Online buffer-tank level/concentration monitoring | Ultrasonic level + density meter | 1 | set | 3.20 | 3.20 | Interlocked with feed pump |
| Subtotal | 121.80 | ||||||
II. Grit removal & oil extraction
SAND REMOVAL & OIL EXTRACTION| No. | Equipment | Model / spec | Qty | Unit | Unit price (10k RMB) | Amount (10k RMB) | Notes |
|---|---|---|---|---|---|---|---|
| 8 | High-concentration cyclone grit remover | XLCS-2, Q=15m³/h | 2 | pc | 6.80 | 13.60 | Slurry overflows, grit discharges below |
| 9 | Screw press dewaterer | ZNJ-315, grit dewatering | 1 | pc | 17.80 | 17.80 | Cake moisture ≤60% |
| 10 | Constant-temp heating reactor | V=20m³, coil heating + agitation + insulation | 2 | pc | 12.60 | 25.20 | 70–80℃ constant temp |
| 11 | Heating-tank pump | ZJB-11 | 2 | pc | 1.50 | 3.00 | |
| 12 | Three-phase horizontal disc centrifuge | WLL-450, Q=10–12m³/h | 2 | pc | 32.80 | 65.60 | One duty, one standby |
| 13 | Insulated oil/grease storage tank | V=20m³, electric tracing + insulation | 2 | pc | 8.60 | 17.20 | Crude oil/grease buffer storage |
| 14 | Oil discharge / loading pump | KCB-135 | 2 | pc | 1.40 | 2.80 | |
| 15 | Heat exchange unit | Hot-water/steam dual use, 1.5MW | 1 | set | 11.00 | 11.00 | Feeds the heating tank |
| Subtotal | 156.20 | ||||||
III. Hydrolysis/acidification & anaerobic digestion
HYDROLYSIS & ANAEROBIC DIGESTION| No. | Equipment | Model / spec | Qty | Unit | Unit price (10k RMB) | Amount (10k RMB) | Notes |
|---|---|---|---|---|---|---|---|
| 16 | Hydrolysis/acidification tank | V=250m³, with agitation and insulation | 1 | tank | 32.00 | 32.00 | HRT≈4d |
| 17 | Mesophilic anaerobic digester | V=1000m³, steel bolted, gas-tight roof, heating coils | 2 | tank | 78.00 | 156.00 | HRT≈22d, 35±2℃ |
| 18 | Digestion feed pump | Screw pump, Q=10m³/h VFD | 2 | pc | 4.20 | 8.40 | One duty, one standby |
| 19 | Side-entry agitator | 7.5kW, mechanical seal | 6 | pc | 6.20 | 37.20 | 3 per tank |
| 20 | Biogas gas-water separator & collection header | Including condensate drain and flame arrester | 1 | set | 13.00 | 13.00 | |
| 21 | Dry desulfurization tower | Iron-oxide desulfurization, one duty one standby | 2 | pc | 8.20 | 16.40 | Outlet H₂S≤20ppm |
| 22 | Double-membrane gas holder | V=1500m³, membrane constant pressure | 1 | set | 52.00 | 52.00 | Including membrane, blower, safety valve |
| 23 | Biogas distribution valve group | Flame arrester, pressure regulation, flow metering | 1 | set | 10.00 | 10.00 | |
| 24 | Biogas hot-water boiler | 1.4MW, for digestion heating | 1 | pc | 28.00 | 28.00 | Backup heat source |
| 25 | Hot-water circulation pumps & piping | Including insulation | 1 | set | 16.00 | 16.00 | |
| 26 | Biogas generator set | 250kW containerized, incl. waste-heat recovery | 1 | set | 72.00 | 72.00 | Power + jacket-water waste heat |
| 27 | Distribution & grid-connection cabinet | Generator connection, low-voltage grid tie | 1 | set | 26.00 | 26.00 | On-site self-generation/self-use |
| Subtotal | 467.00 | ||||||
IV. Odor collection & deodorization
ODOR CONTROL| No. | Equipment | Model / spec | Qty | Unit | Unit price (10k RMB) | Amount (10k RMB) | Notes |
|---|---|---|---|---|---|---|---|
| 28 | Odor collection branches & header | FRP/304, incl. control valves | 1 | set | 18.00 | 18.00 | Covered collection over tanks |
| 29 | Scrubber | Two-stage acid + alkali wash | 2 | pc | 11.00 | 22.00 | Removes H₂S, NH₃ |
| 30 | Biofilter | 600m³ media, incl. air distribution | 1 | tank | 46.00 | 46.00 | Residence time ≥25s |
| 31 | Odor centrifugal fan | Q=15000m³/h, VFD | 2 | pc | 5.50 | 11.00 | One duty, one standby |
| 32 | Stack | H=15m, incl. sampling ports and ladder | 1 | tank | 4.00 | 4.00 | Compliant discharge |
| Subtotal | 101.00 | ||||||
V. Control & utilities
CONTROL & UTILITIES| No. | Equipment | Model / spec | Qty | Unit | Unit price (10k RMB) | Amount (10k RMB) | Notes |
|---|---|---|---|---|---|---|---|
| 33 | PLC centralized control system | Siemens S7-1500 + host PC + HMI touchscreen | 1 | set | 32.40 | 32.40 | Centralized control-room monitoring |
| 34 | Field instruments | Level/temperature/pH/flow/gas detection | 1 | set | 9.60 | 9.60 | Including combustible gas alarm |
| 35 | Control cabinets, power cables & tray | MNS cabinets + YJV cables | 1 | set | 15.00 | 15.00 | |
| 36 | Process piping, valves & supports | 304 stainless / carbon steel | 1 | set | 22.00 | 22.00 | |
| 37 | Platforms, ladders, railings & anti-corrosion insulation | Hot-dip galvanized + topcoat | 1 | set | 16.00 | 16.00 | |
| 38 | Air compressor & air receiver | 1.0m³/min | 1 | set | 3.60 | 3.60 | Air supply for pneumatic valves |
| 39 | Fire-fighting & safety facilities | Fire extinguishers, eyewash, signage | 1 | lot | 6.00 | 6.00 | |
| Subtotal | 104.60 | ||||||
Equipment subtotal
SUBTOTAL BY SYSTEM| System | Amount (10k RMB) | Share |
|---|---|---|
| I. Receiving & pulping system | 121.80 | 12.8% |
| II. Grit removal & oil extraction | 156.20 | 16.4% |
| III. Hydrolysis/acidification & anaerobic digestion | 467.00 | 49.1% |
| IV. Odor collection & deodorization | 101.00 | 10.6% |
| V. Control & utilities | 104.60 | 11.0% |
| Equipment subtotal | 950.60 | 100% |
Equipment quotation summary
This quotation covers only the treatment equipment in the process flow diagram, excluding civil works, buildings, tanks and utilities. Unit prices are ex-works incl. 13% VAT; freight and installation/commissioning, if undertaken by us, are priced separately.
Quotation scope
WHAT IS INCLUDED- All process equipment across five systems, 39 items (incl. standby units)
- Equipment body, standard accessories, special tools and spare parts
- Technical specifications, operation & maintenance manual, factory inspection and pressure-test reports
- Incl. 13% VAT
- Civil works, buildings, tanks, equipment foundations and berms
- Freight, unloading, lifting and installation/commissioning
- 10kV external line and transformer capacity upgrade
- Advanced digestate treatment; food-waste collection vehicles
Total equipment price
- Investment per capacity19.0 10k RMB/(t·d)
- Equipment investment per tonRMB 576/(t·yr)
- Annual throughput16,500 t
- Pricing basisEx-works · incl. tax
If we also undertake these, priced separately (not in the above)
OPTIONAL| Item | Basis | Amount (10k RMB) |
|---|---|---|
| Freight | 2% of equipment cost | 19.01 |
| Installation & commissioning (incl. site supervision, integrated commissioning and operator training) | 8% of equipment cost | 76.05 |
| Both subtotal | 95.06 | |
Operating cost
Allocated over 16,500 t/yr. Basis: excluding depreciation and financing, including power, water, chemicals, labor, maintenance, and digestate/residue disposal.
Cost breakdown
OPEX BREAKDOWN| Cost item | RMB/t | 10k RMB/yr | Basis |
|---|---|---|---|
| Electricity (at RMB 0.65/kWh) | 71.5 | 118.0 | Plant power 5,500 kWh/d; biogas generation offset shown under revenue |
| Water (process make-up & wash) | 1.8 | 3.0 | Make-up 20 m³/d × RMB 4.5 |
| Chemicals (desulfurization, deodorization, flocculation) | 18.0 | 29.7 | ~RMB 900/d |
| Labor wages & benefits | 87.3 | 144.0 | Staff 15 × RMB 8,000/month |
| Equipment maintenance & spares | 16.1 | 26.6 | 2.5%/yr of original equipment value |
| Digestate disposal | 27.5 | 45.4 | 52 m³/d × RMB 25/m³ (land application or discharge) |
| Inorganic impurities & grit off-site | 6.7 | 11.1 | 4.0 t/d × RMB 120/t |
| Testing, monitoring & admin | 4.8 | 8.0 | Environmental online monitoring, routine testing |
| Total operating cost | 233.8 | 385.8 | |
| Depreciation (15-yr straight-line, residual 0) | 38.4 | 63.4 | Based on equipment price RMB 9,506,000 |
| Full cost | 272.2 | — |
Revenue & payback
Three revenue streams: selling oil, selling (saving) power, and collecting the tipping fee. The tipping fee is a policy variable, so a sensitivity analysis is shown separately below.
Annual operating revenue
ANNUAL REVENUE| Revenue item | Quantity | Unit price | 10k RMB/yr | Note |
|---|---|---|---|---|
| Crude oil/grease sales | 594.0 t/yr | RMB 7,250/t | 430.65 | 1.8 t/d × 330 days |
| Biogas power (offset purchased power) | 1,980,000 kWh/yr | RMB 0.65/kWh | 128.70 | 6,000 kWh/d × 330 days, self-use |
| Waste treatment service fee | 16,500 t/yr | RMB 180/t | 297.00 | Per local subsidy standard, negotiable |
| Digestate fertilizer sales | — | — | 10.00 | At a conservative value |
| Total annual operating revenue | 866.35 | |||
Revenue mix
REVENUE MIXOil and the tipping fee are two legs: oil price follows the market (recent crude oil RMB 6,000–8,000/t), while the tipping fee is set by local fiscal subsidy policy. Relying on oil sales alone, the project is marginal; once the tipping fee arrives, payback shortens markedly.
Bottom line
BOTTOM LINE| Annual operating revenue | 866.35 10k RMB |
| Annual operating cost | -385.8 10k RMB |
| Annual net operating cash flow | 480.55 10k RMB |
| Annual depreciation | -63.4 10k RMB |
| Annual pre-tax profit | 417.18 10k RMB |
| Static payback (on equipment price) | 2.0 years |
Sensitivity: at different tipping fees
SENSITIVITY| Scenario | Tipping fee (RMB/t) | Net cash flow (10k RMB) | Payback (equipment basis) |
|---|---|---|---|
| Purely market-based collection (no tipping fee) | 0 | 183.5 | 5.2 years |
| Tipping fee RMB 120/t | 120 | 381.5 | 2.5 years |
| Tipping fee RMB 180/t (baseline) | 180 | 480.5 | 2.0 years |
| Tipping fee RMB 240/t | 240 | 579.5 | 1.6 years |
Note: payback is computed as "equipment price ÷ annual net operating cash flow", excluding loan interest and income tax. If the owner’s civil works, buildings, tanks and utilities are included (typically RMB 8–9 million for this scale), total project investment is ~RMB 18 million, and the payback for the four scenarios above is about 9.9 / 4.7 / 3.8 / 3.1 years respectively. Civil works are outside this quotation and are provided for investment-decision reference only.
Supply scope & commercial terms
Writing down "who is responsible for what" clearly is more valuable than pushing the price down.
Our supply scope
INCLUDED- Full-line equipment for receiving, pulping, grit removal, heating and three-phase oil extraction
- Hydrolysis/acidification tank, 2×1000m³ mesophilic digester with agitation and heating systems
- Biogas upgrading (desulfurization, gas-water separation), 1500m³ double-membrane gas holder
- 250kW biogas generator set (incl. waste-heat recovery), 1.4MW biogas boiler
- Odor collection, scrubber, 600m³ biofilter, 15m stack
- PLC centralized control, field instruments, control cabinets and power cables
- Process piping/valves, platforms/ladders, anti-corrosion insulation
- Transport, installation/commissioning, operator training (2 weeks)
Not included in this quotation
EXCLUDED- Civil works, steel-structure buildings, tanks, equipment foundations and berms
- 10kV external line and transformer capacity upgrade
- Advanced digestate treatment (membrane concentration / MBR), to be discussed if needed
- Food-waste collection vehicles and bins
- Site landscaping, perimeter wall, guard house, weighbridge
- Third-party costs: EIA, energy assessment, acceptance, etc.
- Operating-period water, power, chemicals and labor
- Work stoppage due to force majeure or owner reasons
Commercial terms
COMMERCIAL| Quotation validity | 30 days (steel and stainless prices are volatile; re-pricing needed beyond this) |
| Delivery | Shipment 90 days after contract effectiveness and advance payment; digester tanks 120 days |
| Payment terms | 30% advance / 40% before shipment / 25% on installation completion / 5% retention |
| Warranty | Equipment 12 months (wearing parts excluded); digester tanks 5 years |
| Pricing basis | Incl. 13% VAT, incl. freight (prefecture-level cities in China) |
| Acceptance criteria | Continuous 72-hour full-load trial; throughput, oil recovery and biogas output meet design |
To be provided by the owner
BY OWNER- Site general layout, geotechnical report, confirmed power supply capacity
- Feed lab data (moisture, oil content, impurity rate)
- Digestion effluent outlet (land-application agreement / discharge quota)
- Grease off-take intent (recommend locking the buyer and price in advance)
- Temporary construction water/power and site access road conditions