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AD at abattoir – Feasible?
Otto Hager
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Content of interaction
• AD as solution for waste management at abattoir
• ibert Cavalier abattoir biogas system
• Feasibility?
• What are the pitfalls/ most critical issue ?
• Back door
• Reference plants – ibert Cavalier, etc.
• Conclusion
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Anaerobic Digestion?
“Product” of natural process of decomposing of
organic material in the absence of O2
Biological process that convers carbohydrates, fats
and proteins into methane CH4 and CO2
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Golden rule of AD
To Act immediately and consistently
BUT
with patience
this will
achieve results
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ibertCavalier Biogas process/ system
Abattoir
Mixing pit
Waste
material
CHP house Phs1
135kW
Bio-gas
Storage tank
Digestate
bert
Digester I
Biogas
Electricity Heat
bert
Digester II Phase 2
Solid fraction
Fertilizer
CHPhousePhs2
250kW
Settlement
dams
Liquid fraction
Within COD’s
BOD’s
Cooker
Settlement
dams
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Feasibility game changers
• Price of service & energy is critical - MUST move away
from cheaper than Eskom - why?
• Waste processing cost – gate fee – laws must be
enforced - please
• Green – Carbon tax – must be realized
• Tri-generation
• Electricity sales – reality
• Heat – 80C - reality
• Cold - 9-12C via adsorption cooling – chiller plant
• Organic compost – not reality YET !! must become a
sought after product
• Funding period must be long term 10y +
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Most critical operational aspect
Material = fuel •Consistency – seasonality •Availability – 365day/y •Quality – directly linked to gas production •Stock-pile ? JIT
Reality
•It’s all variables !!!!
•animal size varies, seasonality, peaks & valleys, strikes, draughts
Contracting
•Critical thinking/ planning of all eventualities
Funding
•Ensure funders understand time-lines & flexibility
•Include 1st year operation & maintenance cost !!!
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Critical technology issues – effects
• Type & quantity of material – Fuel begin and end
• Operation – skills, back-up NOW not tomorrow
• Workforce – 24/7 – weekends, holidays/ strikes –
infrastructure, transport, accommodation, safety, theft,
etc. bacteria does not know when its Christmas
• Complexity of technology – Africanize
• Maintenance & break-downs – simple
• End-use - can not only be electricity – tri-gen
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Financial of ibertCavalier
Plant
• Process plant AD = 1000m3 process +- 30t/day
• +- 170m3/hr at full output
• CHP’s 135 + 225 kW = 360kW el
• Budget cost phs1 R12,5m actual R16m
• Phase 2 budget R12m actual R12m
Low operation cost >10c/kWh / self usage >6%
Revenue streams
• Gate fee
• Energy sales
• CER – carbon tax possible • Organic Fertilizer - not realizing
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Back-doors – life line
Waste supply •Every bodies potatoes the larges but reality is different •Must have alternative feedstock or penalties Funders •keep them close speak to them, make sure they understand what you telling them, the have a different decoders Take off/ client payments •Must find workable process must be win-win Legalities •Enforce your agreement don’t let it slip – it will bite you •Spend extra week on definitions and clarity before signing agreement don’t rush - it will save years in long-run
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Reference sites South Africa
Plant #1 Meat to Market Jan Kempdorp - 2010
600m3 AD, 135 kW CHP, 15 t/day slaughter waste
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Plant #2 Hessequa Abattoir – Riverdale - 2014
400m3 AD, 50 kW CHP, 10 t/day slaughter waste
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Plant #4&5 Cavalier Abattoir – Cullinan - 2015/17
2 x 500m3 AD, 360 kW CHP, 35 t/day abattoir waste
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Plant #3 No2 Piggeries – Peninsula – Queenstown - 2015
600m3 AD, 190 kW CHP, 35 t/day pig manure
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Plant #6 Zandam Cheese & Piggery (W/Cape) 2016
1 x 400m3 AD, 75 kW CHP, 30 t/day pig manure
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Plant #7 Thorny hill KZN – energy crop - 2016
200m3 AD, 16 kW 2,5t/d Napier grass
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Conclusion
• AD at abattoir is feasible waste management option
• Critical to select correct technology and operational
process (the devil is in the details)
• All energy must be utilised - tri-gen most feasible
• Must be partnership – can’t be one sided
• Funding is critical must have some equity but flexible loan
conditions – something WILL GO WRONG – plan for it!
Will I do it again? YES, BUT I will spend more time on
contracts before I sign !!