Ziel
The aim of the project is to demonstrate the technical and economical feasibility of a unique energy-saving purification phase in the whey-products production process. This solution is based on a combined use of anaerobic and aerobic principles which results in a considerable decrease of energy consumption. This decrease has 3 components: - less energy needed for the existing aeration (airpumps) and auxiliary equipment in the aerobic phase; - production of methane gas which can directly be used in our cogeneration plant; - a considerable reduction of sludge which has also energy saving effects; less energy is needed for the treatment of the sludge;
Borculo Wheyproducts introduces the first application of this technique in a wheyproducts production process (dairy industry). Besides the large quantity of energy saved, the proposed approach has many other positive by-effects, mainly from an environmental point of view.L%
The anaerobic step, main part of the combined anaerobic/aerobic plant, will be cheaper and more reliable than the existing single aerobic treatment. This is because unlike aerobic treatment systems, anaerobic treatment does not require aeration, a big consumer of energy and the single largest operation expense. Combined with the energy savings involved with the working up, transportation and distribution of sludge, total operating costs are reduced further. A third important energy saving aspect in relation with the proposed technique is the production of generated methane gas and its direct use in our cogeneration plant.
A. Aeration
Substantial energy savings will be accomplished by the fact that the purification will be executed by the anaerobic step, which does not consume much energy. IX/92 the daily demand of energy needed for aeration was 5,567 KWh. At the end of 07/93 the daily demand of energy for aeration was reduced by 3,449 kWh, to 2,118 kWh. An extra energy consumptionwas needed for several parts of the anaerobic installation of about 900 kWh. This results in a daily net energy saving of 2,550 kWh. On annual base an energy saving of 365 x 2,550 = 930,750 kWh can be obtained.
B. Less energy for sludge treatment
As far as the reduction of sludge is concerned, positive energy saving effects can be attained through less working up of sludge, less transportation and distribution to agricultural land. In the past situation the total operating costs of sludge treatment amounts f 450,000.--. The energy component is about 8% = f 36,000.--. A reduction of 85% leads to annual savings on energy of 85% x f 36,000. = f 30,600.-.
C. Production of methane gas
Other major savings can be attained through the production of biogas (methane). As a result of specific research during the pilot plant experiments it is known that the generated fuel can be used without further treatment. Daily methane gas production as a result of the anaerobic treatment amounts to 2,750 m3. In the future a daily methane gas production of 3,100 m3 can be obtained, because of a permanent use of the produced gas. At this moment a certain amount of gas had to burn unuseful in the weekends. When the total amount of gas is used, an annual saving of 70% x 3,100 x 365 = 792,050 A.E. can be obtained.
Other energy saving aspects.
Other favourable effects in relation with the operational costs will be caused by lower levies to be paid to the waste water treatment authorities. These levies are proportional to the amount of waste. In the present situation the levies amount to f 252,000.--. In the new situation a reduction of 66.67% is foreseen, thus leading to an annual levy of f 84,000.-. This indirectly implicates energy savings from a society point of view.
Implementation of the proposed system will enable further energy savings in the future. Especially in dairy industry, purification plants are respected as a part of process.
BORCULO WHEYPRODUCTS.
Borculo Wheyproducts is an internationally oriented company that produces a large variety of quality products from cheese-whey. In this field Borculo Wheyproducts has a primary role in the Dutch dairy industry. Borculo Wheyproducts produces e.g. Iactose, protein powders, and fat powders as a semi manufactured article for the pharmaceutical industry and feedstuffs for (young) animals. As raw material cheese whey, a by-product of cheese production, is used. This cheese-whey is from EC origin (NL, DK, BRD, IRE). The company aims strongly at developing new products and new processes, this with an open eye to the developments in the market. Borculo Wheyproducts is specialized in the production of special products. Since 1962 the activities of Borculo Wheyproducts are solely related to the processing of cheese-whey, which at itself is a unique feature, worldwide. Borculo Wheyproducts processes about 3.000 million litres of whey per year, which makes Borculo Wheyproducts the largest whey products company in the world.
BRIEF TECHNICAL DESCRIPTION AND SIZE OF THE PROJECT
- Energy saving in the whey products production process by introducing new upflow anaerobic sludge blanket purification technique.
- First application of this technology in dairy industry.
- Energy saving accomplished by
* less aeration in existing aerobe sludge treatment phase
* use of methane gas which results from the anaerobic process
* decrease of energy needed for post-treatment of sludge.
PROSPECTS OF SUBSEQUENT COMMERCIAL EXPLOITATION
If successful, this technique can be applied in all larger dairy companies where similar process waste streams need lots of energy to be treated. Thus, on E.C.-scale a total saving of energy can be accomplished at about 150 larger companies in dairy industry. Also other foodstuffs industries can benefit from these results.
IMPACT OF THE PROJECT ON THE ENVIRONMENT
- Substantial decrease of waste sludge, thus having a very positive environmental impact.
CAPABILITY OF THE PROMOTORS
Borculo Wheyproducts as well as Paques B.V. both have many contacts and experience in dairy industry. Borculo Wheyproducts is a cooperative enterprise which is supplied by many national and European cheesemaking industries. Besides the supplier Paques B.V. has many business associates (license-partners) abroad who are entitled to exploit eventual licenses involved in this project. Moreover the dairy industry is equipped with good communication lines and organizations with tasks including dissemination of new developments in this branch.
Wissenschaftliches Gebiet (EuroSciVoc)
CORDIS klassifiziert Projekte mit EuroSciVoc, einer mehrsprachigen Taxonomie der Wissenschaftsbereiche, durch einen halbautomatischen Prozess, der auf Verfahren der Verarbeitung natürlicher Sprache beruht. Siehe: Das European Science Vocabulary.
CORDIS klassifiziert Projekte mit EuroSciVoc, einer mehrsprachigen Taxonomie der Wissenschaftsbereiche, durch einen halbautomatischen Prozess, der auf Verfahren der Verarbeitung natürlicher Sprache beruht. Siehe: Das European Science Vocabulary.
Dieses Projekt wurde noch nicht bei EuroSciVoc klassifiziert.
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Finanzierungsregelung (oder „Art der Maßnahme“) innerhalb eines Programms mit gemeinsamen Merkmalen. Sieht folgendes vor: den Umfang der finanzierten Maßnahmen, den Erstattungssatz, spezifische Bewertungskriterien für die Finanzierung und die Verwendung vereinfachter Kostenformen wie Pauschalbeträge.
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7271 AB BORCULO
Niederlande
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