the practical guide to ad (index)

An introduction to developing and operating anaerobic digestion facilities in the UK

The PracTical Guide To adFirsT ediTion

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Welcome

www.adbiogas.co.uk 3The pracTical guide To ad

Welcome to the first edition of ‘The practical guide to ad’, an all-encompassing introductory reference tool for those developing and operating anaerobic digestion facilities in the uK. Whether you have a basic understanding or in-depth technical knowledge of the industry, this handbook is designed as a hands-on guide to help you with every stage of your project.

With more than 40 contributors, a team of reviewers and external stakeholders feeding-in their expertise and knowledge, this reference tool is produced by the industry for the industry. it is intended to be a high-level living document and one which we hope will become a vital resource for all those involved in the ad and biogas industry.

My special thanks go to all the contributors, adBa members and the editorial team who have helped put together this first issue of ‘The practical guide to ad’; it has required a lot of hard work, perseverance and dedication. particular thanks, too, to Terry Brownhill for kick starting the guide in the first place and tirelessly supporting the project at every stage. also, a big thanks go to the sponsors of this edition whose support allowed us to cover a large proportion of the production costs enabling us to offer the publication to members free of charge and to non-members at a reduced rate.

i hope you find the information in the guide useful and that it will help support the development and operation of ad plants across the uK. please do not hesitate to contact us with any comments or suggestions for the next updated issue which will be published in 2014.

Best wishes,

Charlotte Morton, Chief Executive, ADBA

suPPorTinG The GrowTh in ad

Contact us:

canterbury court,Kennington park Business centre,1-3 Brixton road, london, SW9 6deT+44 (0)203 176 0503 e [email protected] www.adbiogas.co.ukFollow us on Twitter: @adbiogas

Editorial team

EditorKirsty Sharpe

Features EditorKate O’Reilly

Chief ExecutiveCharlotte Morton

Policy ManagerMatt Hindle

Commercial DirectorLouise Wallace

Technical EditorZoë Lenkiewicz

Sales ManagerJamil Ahad

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1 whaT is anaeroBic diGesTion? 11

1.1 What is anaerobic digestion? 12

1.2 The AD process 13

1.3 AD – a proven technology 14

2 whY anaeroBic diGesTion? 17

2.1 Introduction 18

2.2 AD benefits everyone 182.2.1 Benefits to farming 182.2.2 Benefits to the public 192.2.3 Benefits to local authorities and government 192.2.4 Benefits to business 19

2.3 Financial incentives 192.3.1 The Renewables Obligation (RO) and Feed-in Tariff (FIT) 202.3.2 Levy Exemption Certificates (LECs) 202.3.3 Heat from biogas combustion: renewable heat

incentive (RHI) 202.3.4 Biomethane grid injection: renewable heat

incentive (RHI) 202.3.5 Biomethane as a transport fuel: Renewables

Transport Fuels Obligation (RTFO) 21

2.4 Government policy 21

3 FeedsTocKs 23

3.1 Introduction to feedstock 243.1.1 Composition 243.1.2 Sourcing feedstock 243.1.3 PAS 110 25

3.2 Feedstock by sector 253.2.1 Agricultural – animal waste 253.2.2 Agricultural – plant based 263.2.3 Food waste post-manufacture 263.2.4 Organic commercial and industrial waste 273.2.5 Household food waste 273.2.6 Woody materials and green waste 273.2.7 Sewage and wastewater sludge 28

3.3 Feedstock treatment and ABPR requirements 283.3.1 Pre-treatment processes 283.3.2 Animal by-products 293.3.3 Hub and Pod Digestion and ABPR 313.3.4 AD processes compared to pasteurisation requirements 313.3.5 Feedstock pre-treatment systems (generic) for AD 323.3.6 Category 2 treatment – rendering animal wastes 34

3.4 Handling of feedstock general requirements 353.4.1 Storage of feedstock 35 3.4.2 Parasites and pathogens in feedstock 36 3.4.3 Transferring waste to the digestion plant 36 3.4.4 Cost considerations 36

4 The anaeroBic diGesTion Process 39

4.1 Characteristics of AD systems 404.1.1 Operating temperature 404.1.2 Digester feed 404.1.3 Loading rate 404.1.4 Hydraulic retention 40

4.2 Configuration 414.2.1 Liquid digestion configurations 414.2.2 Wet digestion configurations 414.2.3 Dry digestion configurations 42

4.3 Operational considerations – wet digestion 434.3.1 Screening and depackaging 434.3.2 Grit 444.3.3 Gas system design 444.3.4 Operating pressure 454.3.5 Purging 454.3.6 Hydrogen sulphide in biogas 464.3.7 Design of slurry pipework 464.3.8 Heating 464.3.9 Mixing 474.3.10 Rheology 474.3.11 Types of wet digester mixing 484.3.12 Whole digestate storage 504.3.13 Dewatering 504.3.14 Odour 514.3.15 Foaming 51

4.4 Operational considerations – dry digestion 524.4.1 General considerations with dry digestion 52 4.4.2 Plugflow systems 52 4.4.3 Static dry AD systems 55

4.5 Digester monitoring 564.5.1 pH 56 4.5.2 Carbon:nitrogen (C:N) ratio 57 4.5.3 Methane concentration 574.5.4 Volatile fatty acids 574.5.5 Alkalinity buffer 574.5.6 Ammonia concentrations 574.5.7 Trace elements 574.5.8 Retention time in digester 57

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5 ProducinG and usinG BioGas 59

5.1 Benefits of biogas 60

5.2 Biogas composition 605.2.1 Methane 60 5.2.2 Water 605.2.3 Hydrogen sulphide 60 5.2.4 Oxygen 615.2.5 Ammonia 61

5.3 Variations in biogas composition 615.3.1 Factors affecting biogas yield 63

5.4 Biogas cleaning prior to use 635.4.1 Hydrogen sulphide removal 645.4.2 Siloxane (silicon – oxygen – methane) removal 64

5.5 Biogas monitoring 655.5.1 Which gases need to be monitored and why? 655.5.2 How is biogas monitored? 65

5.6 Introduction to using biogas 65

5.7 Combustion to generate heat only 66

5.8 Combined heat and power (CHP) 665.8.1 Power generation 665.8.2 Parasitic power 665.8.3 Heat use 675.8.4 Jacket cooling water 685.8.5 Flue gas heat recovery 685.8.6 Steam generation 68

5.9 Combined heat, power and cooling 685.9.1 Generating additional electricity from ‘waste heat’ 695.9.2 Gas engine availability 705.9.3 Maintenance contracts versus independent service 715.9.4 Electricity connection 71

5.10 Biomethane 715.10.1 Upgrading biogas to biomethane 715.10.2 Injecting biomethane to the grid 735.10.3 Gas quality monitoring and energy metering 745.10.4 Biomethane market 75

5.11 Biogas as a vehicle fuel 76

5.12 Future trends 77

6 diGesTaTe 81

6.1 Introduction 82

6.2 Benefits of digestate for agricultural land 83

6.3 Separating the digestate 836.3.1 Whole digestate 846.3.2 Liquor 846.3.3 Fibre 85 6.3.4 Cake 85

6.4 Separation techniques 856.4.1 Screw press 86 6.4.2 Belt press 866.4.3 Centrifuge 866.4.4 Bio-drying 866.4.5 Evaporation 866.4.6 Membrane filtration and reverse osmosis 866.4.7 Chemical separation 86

6.5 Application of digestate 866.5.1 Bandspreading 876.5.2 Tankering 876.5.3 Trailing shoe 876.5.4 Dribble bars 876.5.5 Disc injectors 876.5.6 Tine injectors 876.5.7 Manure-type spreaders 87

6.6 Variations in digestate with sector 876.6.1 Digestate from farm slurries and crops 886.6.2 Digestate from the water industry 886.6.3 Digestate from source-segregated waste 896.6.4 Digestate from mixed waste 90

6.7 Storage and transport 906.7.1 Storing liquid digestate 906.7.2 Storing dewatered digestate 906.7.3 Transporting digestate 90

7 PlanninG 93

7.1 Is planning permission required? 94

7.2 Progressing a planning application 947.2.1 Pre-application discussions with the local

planning authority 947.2.2 Preparation of the submission 947.2.3 Submission of a screening and scoping opinion 94 7.2.4 Development of proposals 957.2.5 Consultation 957.2.6 Refinement of proposals 967.2.7 Determination period 967.2.8 Post screen 96



Contents

8 PerMiTTinG 99

8.1 England and Wales 100

8.2 Exemptions 1008.2.1 T24 exemption for on-farm AD 1008.2.2 T25 exemption for off-farm AD 100 8.2.3 Exemptions for spreading digestate 101

8.3 Standard rules environmental permits 1018.3.1 Standard rules for on-farm AD installation (SR2012 No9) 101 8.3.2 Standard rules for on-farm AD waste operation (SR2012 No10) 102 8.3.3 Standard rules for off-farm AD installations (SR2012 No11) 102 8.3.4 Standard rules for off-farm AD waste operations (SR2012 No12) 102 8.3.5 Standard rules for storage of digestate from AD plants (SR2010 No17) 103 8.3.6 Standard rules for the use of mobile plant for land spreading (SR2010 No4) 103 8.3.7 Standard rules for combustion of biogas as a fuel in engines at a sewage treatment works (SR2009 No4) 103 8.3.8 Health warning 103

8.4 Bespoke environmental permits 1038.4.1 Waste facility/operation 103 8.4.2 Schedule 1 Activity (Listed Activity) 104

8.5 Permitting in Scotland and Northern Ireland 1048.5.1 Scotland 1048.5.2 Northern Ireland 104

9 FundinG The ProjecT 105

9.1 Finance 1069.1.1 Bank or debt finance 1069.1.2 Equity finance (investment funds) 1069.1.3 Reducing the amount of collateral required 106

9.2 Financial incentives 1079.2.1 Feed-in Tariff (FIT) 1079.2.2 Renewables Obligation Certificates (ROC) 1099.2.3 Renewable Heat Incentive (RHI) 1099.2.4 Renewable Transport Fuels Obligation (RTFO) 110

9.3 Insurance 1119.3.1 Insurance market overview 1119.3.2 Risks to be considered and insurance solutions 1119.3.3 Assets 112 9.3.4 Income 112 9.3.5 Liabilities 112 9.3.6 Legal protection 112

10 leGal and conTracTual MaTTers 115

10.1 Legal structures 11610.1.1 Corporate structures 11610.1.2 Contract structures 116

10.2 Joint ventures 11610.2.1 Control of decision making 11710.2.2 Project financing 117 10.2.3 Deadlock resolution procedures 117

10.3 Bank funding/debt finance 11710.3.1 Documentation required for AD project financing 117 10.3.2 Lender’s advisors 119

10.4 Equity funding 119

10.5 Feedstock supply 12010.5.1 Feedstock specification 12110.5.2 Delivery 12110.5.3 Unloading, weighing and inspection 12110.5.4 Transfer of title and risk 12110.5.5 Term and price 121 10.5.6 Shortfall in feedstock 12110.5.7 Force majeure 12110.5.8 Project lenders 12110.5.9 Summary 122

10.6 Construction, engineering, operation and maintenance contracts 122

10.7 Real estate issues 12210.7.1 Site identification 12210.7.2 Legal process 12210.7.3 Option 12310.7.4 Lease 123

10.8 Insolvency and default 12310.8.1 Termination rights 12410.8.2 Turnkey projects 12410.8.3 Residual asset value 12410.8.4 Step-in rights 12410.8.5 Sinking fund 124 10.8.6 Options 124

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11 TraininG 125

11.1 Training overview 12611.1.1 Why train your staff? 12611.1.2 Differences between training, qualifications and

competence 126

11.2 Technical competence requirements for permitted facilities 12611.2.1 England and Wales 127 11.2.2 Scotland 127 11.2.3 Northern Ireland 127

11.3 Identifying training needs 127

11.4 Maintaining and updating knowledge and skills 129

11.5 Who can help? 12911.5.1 ADBA (The Anaerobic Digestion and Biogas Association) 12911.5.2 CIWM (The Chartered Institution of Wastes Management) 12911.5.3 WAMITAB (The Waste Management Industry Training and Advisory Board) 12911.5.4 WRAP (Waste & Resources Action Programme) 129 11.5.5 EU Skills (Energy and Utility Skills) 129 11.5.6 NSA (National Skills Academy) 12911.5.7 AD Portal 129

12 healTh and saFeTY awareness 131

12.1 Key stages in a project and who needs to be involved 13212.1.1 Responsibilities of the different parties 13212.1.2 Safety issues to be addressed at each stage 133 12.1.3 Hazards awareness 138

12.2 Safe design and operability 13812.2.1 Safety management systems and safe systems of work 138

12.3 Regulations 14112.3.1 Implications and application of DSEAR and ATEX 14112.3.2 Biological hazards in the workplace 14412.3.3 Asbestos 14412.3.4 CDM – Construction (Design and Management) Regulations 14412.3.5 Management of health and safety at work 146 12.3.6 Capabilities and training 146

12.4 Managing specific risks 14612.4.1 Working at height 14612.4.2 Confined Spaces Regulations 1997 14812.4.3 Developing a safe system of work 151

13 aPPendix: healTh and saFeTY 153

13.1 An introduction to health and safety 154

13.2 How to use this appendix 154

13.3 Managing health and safety 155

13.4 Slips, trips and falls 155

13.5 Asbestos 156

13.6 Hazardous substances 156

13.7 Falls from a height 157

13.8 Musculoskeletal disorders 157

13.9 Display screen equipment 158

13.10 Noise 158

13.11 Vibration 159

13.12 Electricity 159

13.13 Work equipment and machinery 160

13.14 Maintenance and building work 160

13.15 Workplace transport 161

13.16 Pressure systems 161

13.17 Fire and explosion 162

13.18 Radiation 162

13.19 Stress 163

13.20 First aid and accident reporting 163

ad TerMs and acronYMs 165



Contributors

review TeaM

Dr. Robin Szmidt, Managing Director, Kuttner (UK) Ltd

after studying at the universities of london and Stirling, robin worked for adaS and Sac before joining Kuttner (uK) ltd, a subsidiary of Kuttner gmbh and a licensee for Kompogas

dry-ad. experienced in ad projects worldwide, robin was involved in consultations for paS 100 and paS 110 and is a member of the uK register of expert Witnesses. robin belongs to a number of international industry groups and is chair of adBa’s dry ad Working group.

Dr. Les Gornall, Process Consultant, PROjEN BioEnergy

a Fellow of the Society of Biology, les has been building anaerobic digesters since 1978. in the early 1980’s, his work on farm waste digestion led to ireland’s first full-scale farm digester and in-vessel composter. after a career building fermenters and commissioning numerous iconic and award winning plants as an independent manufacturer, les now heads the technical team at projeN Bioenergy, designing, building and commissioning

anaerobic digesters from farm-scale to 120,000 tpa facilities.

Dorian Harrison, Technical Director, Monsal and ADBA Director

Monsal has the largest team of advanced digestion technology specialists in the uK and is a leading supplier of anaerobic digestion solutions. Monsal technology is becoming widely

recognised as the technology of choice by developers, utilities, county councils, food producers, waste management companies and farmers in the uK, delivering comprehensive turnkey solutions, from design and build through to post-commissioning support and operation.

Terence Brownhill, Director, Eaton Management and ADBA Director

chair of adBa’s Training and Safety Working group, Terence is a business manager with 10 years experience of operations management in the mining and engineering sector, and 28 years

operational and business development experience in the waste management sector. For the past eight years, Terence has been at the forefront of ad project delivery in the uK.

Amaya Arias-Garcia, Engineering Manager, Tamar Energy

With over 12 years experience in developing and implementing engineering solutions in the environmental sector, amaya previously worked as anaerobic digestion development Manager

for Teg environmental and has been involved in the development of a number of ad plants in the uK. Keen to further the successful development of the uK’s ad industry, amaya is a regular speaker at ad conferences and exhibitions and is also chair of adBa’s Best practice Working group.

Claire Henson, Special Advisor, WRAP

an environmentalist with a background in both private and public sector delivery, claire joined Wrap in 2006 with responsibility for procurement and State aid and has since

helped to deliver over three quarters of a million tonnes of new capacity for green and food waste recycling. claire now leads Wrap’s work on all infrastructure development, and provides technical and strategic support to Wrap’s stakeholders.

Mark Bedford, Director, Wardell Armstrong LLP

project director for Wardell armstrong, delivering infrastructure, renewable energy and waste projects, Mark is a chartered Surveyor, chartered Waste Manager, chartered environmentalist

and honorary Fellow of the Society of the environment. Mark’s previous roles include Midland centre chairman of ciWM and non-executive director of the institute of Wastes Management Business Services limited, and he is a former chair of adBa’s planning & permitting Working group.

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Contributors

oTher conTriBuTors

Tom Brassington, ADAS UK Ltd

Matt Hindle, ADBA

Graeme Vincent, Biogen

Paul Stark, Biotec Ltd

Georgie Messent, Bond Pearce

Christopher Towner, Bond Pearce

Esther Kiddle, Bond Pearce

Nick Churchwood, Burges Salmon

Catherine Goode, Burges Salmon

Stephen McCulloch, Chesterfield Biogas

Tina Benfield, CIWM

Claire Poole, CIWM

Alex Marshall, Clarke Energy

Wayne Middleton, Digestate Solutions

Bora Kulac, E.ON Bioerdgas GmbH

Michael Chesshire, Evergreen Gas

David Kinnersley, Fisher German

Tom Burniston, Geotech

Greg Hilton, GG Eco Solutions Limited

Patrick Pierrepont, Hyder Consulting (UK) Ltd

Duncan Wildgoose, Imtech Water, Waste and Energy

Martin Flach, IVECO

Dawn Terry, Local Generation

Linda Coe, Maclay Murray and Spens LLP

Paul Davies ACII, Nviro Insurance & Risk Management Ltd

Carl Thompson, Osborne Clark

Stuart Cleak, Osborne Clark

Campbell Hutcheon, Pinsent Masons

Kate Turner, Pinsent Masons

Nicola Bowen, Projen PLC

Leasley Eaton, Seepex UK Ltd

Stephen Wise, Shanks Waste Management Ltd

Gail Orr, Shanks Waste Management Ltd

Pat Howe, SSE

Adam Bradley, Taylor Vinters

Mike Orr, The Teg Group

Mike Lee, Uniflare Ltd

Marcus Jones, Uniflare Ltd

Ben Sheppard, Walker Morris

Ray Burberry, Wamitab

Stephen Barnes, Wardell Armstrong LLP

David Bridgewood, Wardell Armstrong LLP

David Tompkins, WRAP

Steven Blues, Zebec Biogas

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www.adbiogas.co.uk10 The pracTical guide To ad

FM Bioenergy is delighted to be the sponsor of The practical guide to ad and congratulates adBa and its contributors on producing such an informative and useful guide.

We specialise in ad nutrition, delivering optimum plant output at the least cost of production. Working in both the farm and industrial biogas sectors, we offer a range of services designed to improve and optimise your gas output and as a result, your return on investment.

FM Bioenergy provides its services in cooperation with Schaumann Bioenergy who are the market leading ad nutrition company in germany. With our joint expertise in the field of anaerobic digestion and efficient feedstock conversion both in europe and around the world we are a competent partner for your enterprise.

FM Bioenergy offers the following services:

consulTancYFM Bioconsult provides a specialist ‘start up’ consultancy which will have your plant up and running at full load within 6 weeks from the start of feeding.

nuTrienT Balancecustomised technical solutions including liquid and powder trace elements to correct deficiencies and deliver enhanced fermentation and substrate utilisation.

GasPlan dieT ForMulaTiona unique diet formulation service, delivering the optimum least cost diet to meet the output requirement of your plant. This service also combines a ‘what if’ formulation ability for you to evaluate new raw materials or throughput options in terms of cost benefit decisions.

FeedsTocK suPPlYthe supply of cost effective alternative substrates from the human food and drinks industries throughout the uK.

laBoraTorY servicesfull process control including the complete analysis of feedstock quality and digester nutrients. accurate results from an accredited biogas laboratory according to eN iSo/iec 17025.

Gas leaKaGe deTecTionchecking the methane volatilization on your ad plant helping to ensure safety and higher profits. Methane sensitive cameras and lasers and ir-devices detect every leakage on your plant.

TraininG

training across all aspects of plant nutrition and biology, from centres in the uK and germany.

FM Bioenergy, unit 15a, gelders hall road, Shepshed, loughborough, le12 9Nh.

email: [email protected] phone: 0871 7043317 www.fmbioenergy.co.uk

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