Abattoir waste system
The following section describes a biogas plant that ENSPAR implemented in eastern Europe for a pig breeding and fattening business with abattoir operations. The plant is already in operation and generates highly-efficient, energy-rich biogas. Yielding 800kW, it has an annual capacity to process and ferment up to 32,000 t of abattoir waste.
The biogas plant was integrated on the grounds of the farm – which operates as a hermetic system – in an area set aside exclusively for manure storage. The constructed system is a multi-stage plant for the fermentation of organic waste and renewables based on the anaerobic, wet fermentation method. Particular attention was paid to keep operations low in energy consumption and emissions.
Produced and stored in four stainless steel fermenters, the biogas is fed over four gas turbines installed in the original building. A biological procedure of upstream desulphurisation is applied, and the biogas is then dried; all traces of sulphur are then removed in an activated carbon filter.
The turbine waste heat systems are fitted with cooling and waste heat exchangers. Waste heat is used to ensure hygiene in the abattoir waste, to control the temperature of the fermenters and to heat the sheds, etc.
In addition to the biogas plant, ENSPAR also delivered the technical equipment for substrate treatment and the pasteurisation/sterilisation facilities. The intake area comprises a pit, in which the components to accept, crush and place the abattoir waste in temporary storage are installed. A hall – divided into a white and a black zone – was built to handle treatment. The intake, pump, treatment and control equipment is also installed here.
Multi-stage crushing and thermal treatment are used to process the abattoir waste. Intake of liquid substrates like blood is separate, and they are then sterilised together with the abattoir waste. After a cooling phase, the blend is fed into the biogas plant for fermentation.
The plant control units – also supplied by ENSPAR – are used to monitor, operate and adjust the plant safety devices, sensors and motors. They control the automatic processes, e.g. plant infeed, as well.
An experienced ENSPAR engineer managed the start-up phase, trial operation and on-site support once the plant was complete.