- Process type – Screening, decanting, hydronic separation and harvesting.
- Process setup – see process flow chart
- Feedstock – Fats, oil, and grease (FOG) captured from commercial kitchen’s grease traps, interceptors and lagoons.
- Heat level(s) – Closed loop Hydronic heat exchanger tubes utilizing NO steam. Operating temperatures range from 120°-160° F.
- Cycle time – variable dependent upon degree of grease separation desired and initial temperature of feedstock. Plan on 24 hours to process but range from 18-36 hours.
- Output – variable dependent upon grease content of raw grease trap waste. For planning purposes post processing results are 15% Brown Grease, 5% batter and 80% pasteurized effluent water.
No additional materials, substances, or chemicals (such as polymers) are needed for Greasezilla to process grease trap waste.
Raw GTW can go directly into Greasezilla reactor tanks however efficiency of the system is maximized utilizing decanting by removing approximately 50% of raw GTW that is water.
Received Grease Trap Waste contains 3-10% brown grease by volume. If the raw waste is decanted, then 10-20% can be refined into GZ fuel depending on input characteristics.
Processed GZ fuel is stored in a heated insulated tank, trailer or frac tank. The most common storage vessel is a commercial tanker which is then trucked to and emptied at a fuel depot.
A standard Greasezilla system with two 10k gallon reactors can process 6-8 million gallons a year and be profitable processing as little as 2 million gallons a year depending on input characteristics. Contact company for a system calculator.
Total operating costs are less than 2 cents a gallon.
Greasezilla fuel trades on the Jacobsen commodity exchange as Brown Grease, an advanced biofuel with a moisture content of less than 1%. It is a drop-in substitute for bunker fuel #6, a marine and industrial boiler fuel. However, Greasezilla fuel burns much cleaner than bunker #6 and is in demand by the maritime industry to help meet IMO 2020 standards. Greasezilla burns 5% of the fuel it creates during processing and may also be used for other heating applications in client’s facilities or processes with the use of additional boilers. Greasezilla fuel can also be utilized as feedstock for bio-diesel producers.
The historical 5-year range for Bunker Fuel #6 is $0.75 – $1.20/gallon. Downey Ridge Environmental can provide turnkey management of Brown Grease sales as a service to our clients. Optional heated fuel tanks for pre-market storage available.
Since Greasezilla occupies a small footprint of only 1000 square feet most applications are housed in existing facilities. Only the control unit and boiler need to be housed. In temperate climates reactor tanks may be located outdoors. Mobile systems mounted on flatbed trailers are available.
- Tanks -two 10,000-gallon reactor tanks, approx. 10x13x26 feet
- Boiler- Sub 1 million BTU (can be configured in series)
- Fuel Source – 300-gallon heated tank for Greasezilla fuel standard.
- Cycle time – dependent on client’s needs. Use 24 hours for planning/estimates.
Nominal permitting requirements vary from municipality to municipality for pasteurized effluent discharge, non-flammable fuel storage and limited flue gas emissions.
During normal operation with the reactor cover closed, negative air pressure within the reactor tanks forces odors through an internal filter within the closed system. Customers may opt for a simple charcoal air scrubber to diffuse minimal odors noticeable when the reactor cover is opened, however that is not required.
Greasezilla consumes approximately 4 gallons of GZ fuel per hour during processing. There are minimal electrical needs associated with 7 HP pumps used to fill and drain the reactor tanks and solid-state circuitry employed by controllers.
Most countries, states and some municipalities offer credits for the creation and utilization of advanced biofuels, which is the classification of Greasezilla fuel. Consult your local authorities.
Minimal preventative maintenance consisting of cleaning, burner nozzle replacement and pump lubrication is recommended. Turnkey wear part replacement kits are available through Downey Ridge Environmental for nominal cost. Annual maintenance costs are estimated to be less than $2000.
Greasezilla systems have been operating for 10 years with little or no downtime.
Varies dependent upon input characteristics and decant process. Greasezilla does not affect BOD levels beyond removing high BOD brown grease from the grease trap waste. Greasezilla reduces BOD to extent that brown grease is removed, leaving pasteurized water and effluent for minimal further treatment.
- After processing approximately 80% of the volume in a 10,000-gallon Greasezilla reactor tank is pasteurized effluent water, ready for headworks of a treatment plant.
- The small (approx. 5% by volume) brain or batter layer is an excellent feedstock for anerobic or co-digestion. If neither is utilized, then traditional methods of treatment can be utilized, or it can be processed with the effluent water.
GZ systems have a payback within two years even when operating at only 50% capacity.
Greasezilla is designed for a life cycle of a minimum 20 years.
- Hydronic Separation System (HSS) Dual Reactor 20K (capacity 7.5m/gal/yr)
- HSS Single Reactor 10K decant/processing system (capacity 3.5m/gal/yr)
Greasezilla is engineered to be scalable to meet even higher volume requirements
As part of the initial purchase DRE will provide up to 4 days of onsite training, set-up, installation and testing of the initial run of the system. Clients may request additional days of technician’s/engineer’s time at competitive rates.
- Assists in complying with CFR 40 403.2 (a) “prevent the introduction of pollutants into POTW which will interfere with the operation of the POTW” and: (c) “improve opportunities to recycle and reclaim municipal and industrial wastewater and sludges”
- Assists in complying with CFR 40 403.5: “Prohibited discharges” (b) 3: “solid or viscous pollutants in amounts which will cause obstruction to the flow in the POTW resulting in interference”