BIOGAS production from organic
waste in the European Food And
Beverage (FAB) industry
Poland
Pazera A., Ślęzak R., Krzystek L., Ledakowicz S.
FABbiogas Final Conference
2nd September 2015, Brussels
Project participants
FABbiogas project includes 9 European partner
organizations.
The project is coordinated by the University of
Natural Resources and Applied Life Sciences
in Vienna.
FABbiogas project involve the following countries:
http://www.fabbiogas.eu/en/home/
EMChIE
2015
Tarragona
7th European Meeting on Chemical Industry and Environment, Tarragona, Spain, 10-12 June 2015
The aim of the project
• The creation of a solid information base concerning the
use of waste in the production of biogas, confirming the
industrial energy efficiency, integrated system of biogas
production.
• Identification of the potential use of waste from food and
beverage industry in existing biogas plants and the
preparation of pre-feasibility studies, constituting the
basis for future biogas projects utilizing FaB waste.
EMChIE
2015
Tarragona
7th European Meeting on Chemical Industry and Environment, Tarragona, Spain, 10-12 June 2015
Methodology
•
Two groups targeted: food and beverages producers
and current biogas plant operators
•
The data concerning waste streams of different FAB
industry branches collected from administrative units
(e.g. Marshal Offices from each voivodship).
•
Existing barriers and bottlenecks for developing
biogas production from organic residues in FAB
industry identified on the basis of the questionnaires
and interviews.
•
The kind and amount of used waste from FAB industry
identified and the potential energy yields calculated.
Methodology
• The methane potential was determined as:
n
Q   R i  Li
i 1
where:
Q - methane production potential in the given branch of FAB industry
(m3CH4/year)
Ri - the amount of i-th kind of waste generated in the given branch
(ton/year)
Li - methane production efficiency from i-th kind of waste in a given
branch (m3CH4/ton).
Biogas plant market - Poland
•
Currently there are 58 installations in Poland. Until 2020,
according to the Council of Ministers in Poland 2 500
biogas plants with a total capacity of 980 MWel are
expected to be built.
•
Main problems: collapse in prices of green certificates,
a large reduction in wholesale electricity prices, no yellow
certificates from the beginning of 2013, and the lack of the
RES Act discourage potential investors and are the
reasons of the small number of new biogas plants.
•
The good news is that over the past two years, more than
20 biogas plants were built, and in total: 19 out of 39
agricultural ones use wastes from industry as a feedstock.
Biogas plant market - Poland
•
39 biogas plants in 2011 consumed 469 000 tons of
feedstock:
–
–
–
•
•
277 800 tons was slurry, manure and animal
excrements,
123 200 tons energy crops,
only 68 000 tons was waste from the food processing
industry.
Last year, however, these proportions, began to change
rapidly. The result is that in the first half of 2013,
agricultural biogas plants processed 750 000 tons of
substrates, 369 000 tons of which were waste from food.
This trend is expected to continue, due to the fact that the
corn-based systems are no longer profitable.
Biogas plant market - Poland
3rd quarter 2012 - 59 000 tones waste from agro- food industry,
4th quarter 2012 - 190 000 tones (a threefold increase),
1st quarter 2013 - 369 000 tones, more than half of all substrates
that were used in biogas plants in Poland
http://www.recyclingworksma.com/how-to/business-sectorguidance/hospitality/
http://www.france24.com/en/category/tags-thematiques/food-beverage-industry/
http://www.packagingnews.co.uk/news/pack-and-food-waste-in-grocery-sector-worth-6-9bn/
Biogas plants using waste from food and beverage industry
Identification of waste streams from FaB industry
•
Companies from food and beverage industry that produce more
waste than 500 Mg/year were taken for further analysis.
•
Waste from food and beverage industry are divided into four
categories: processing of fruits and vegetables, dairy, meat
processing and distilleries.
123 companies processing of fruits and vegetables,
97 dairies,
251 meat processing plants ,
93 distilleries.
Companies that produce organic waste from FaB industry in Poland
Fruit and vegetable processing industry
Companies that produce organic waste from FaB industry in Poland
Dairy industry
Companies that produce organic waste from FaB industry in Poland
Meat processing industry
Companies that produce organic waste from FaB industry in Poland
Brevery industry
Characteristics of waste streams
Waste stream
[Mg/year]
500 – 2 000
Waste category
Number of
companies
Methane production
potential [m3/year]
Fruit and vegetable processing
42
3040600
18
92
6
158
241900
4365300
121400
7769200
43
9260600
48
110
38
239
2616300
15894200
3528700
31299800
22
9082800
17
25
13
77
2296100
13061200
2428500
26868600
16
13753400
14
23
36
89
12235100
51253700
40223300
117465500
Dairy industry
Meat processing industry
Brewing industry
Total
Fruit and vegetable processing
2 000 – 5 000
Dairy industry
Meat processing industry
Brewing industry
Total
Fruit and vegetable processing
5 000 – 10 000
Dairy industry
Meat processing industry
Brewing industry
Total
Fruit and vegetable processing
Above 10 000
Dairy industry
Meat processing industry
Brewing industry
Total
Total: 183 403 100 m3/year
Characteristics of waste streams
Waste stream
[Mg/year]
500 – 2 000
Waste category
Number of
companies
Methane production
potential [m3/year]
Fruit and vegetable processing
42
3040600
18
92
6
158
241900
4365300
121400
7769200
43
9260600
48
110
38
239
2616300
15894200
3528700
31299800
22
9082800
17
25
13
77
2296100
13061200
2428500
26868600
16
13753400
14
23
36
89
12235100
51253700
40223300
117465500
Dairy industry
Meat processing industry
Brewing industry
Total
Fruit and vegetable processing
2 000 – 5 000
Dairy industry
Meat processing industry
Brewing industry
Total
Fruit and vegetable processing
5 000 – 10 000
Dairy industry
Meat processing industry
Brewing industry
Total
Fruit and vegetable processing
Above 10 000
Dairy industry
Meat processing industry
Brewing industry
Total
+
+
+
Total: 183 403 100 m3/year
Meat industry in total:
84 574 400 m3/year
=
Managing of organic waste streams in Poland
=
Description of the barriers for biogas plant
operators and FaB producers
•
The procedures of obtaining the permissions for biogas
projects in Poland are usually complicated and
prolonged.
•
The difficulties in obtaining all necessary permits and too
complex administrative and legal procedures.
•
One of the biggest bottlenecks were the large number
of formal requirements and financial barriers.
•
The incompetence of the bank employees concerning
the possibilities of financing the biogas projects
disappointed the biogas investors. Their lack of trust for
biogas projects hamper the obtaining loans for biogas
projects.
Best practice example
Biogas plant in Boleszyn
Year of realisation:
2012
Investment costs:
22 mln PLN
Feed-in tariff electricity: 0.38 PLN/kWh
Biogas production:
4 230 000 m3/year
Methane content:
53%
Installed power:
1050 kWel, 1156 kWth
Digesters:
3x4239 m3
Substrate/year:
20 000 t maize silage,
13 000 t slurry,
7 300 t whey,
3 600 t distillery stillage
Input waste/substrate:
43 900 t/year
Best practice example
Biogas plant in Boleszyn
•
•
•
•
•
•
•
The biogas plant in Boleszyn was built next to the pig farm.
In the process four different co- substrates are stably fermented
yielding high biogas production.
All in all 43,900 tons of maize silage, slurry, distillery stillage and
whey are used to produce 8.5 mln kWh of electricity and 9.2 mln
kWh of heat per year.
In the near future it is planned to expand the biogas plant capacity
to 2 MW.
Currently burdensome slurry formed during the rearing of pigs is
not a problem for local residents, and additionally they receive hot
water, so that the cost of winter heating has significantly
decreased.
Operator from Plock buys electricity.
Heat produced in the biogas plant is also used by the local
distillery.
Best practice example
Biogas plant in Skrzatusz
Year of realisation:
2011
Investment costs:
13 mln PLN
Feed-in tariff electricity: 0.38 PLN/kWh
Biogas production:
2,058,600 m3/year
Installed power:
526 kWel, 558 kWth
Digesters:
3795 m3
Substrate/year:
15800 t distillery stillage,
2700 t carrot pomace,
5500 t potato pulp,
5500 t corn silage,
2100 t waste protein
Input waste/substrate:
33 600 t/year
Best practice example
Biogas plant in Skrzatusz
 The desire to manage waste from a nearby distillery, rotten fruit and
vegetables (the so-called plant-waste) from supermarkets resulted in the
construction of the first agro-industrial biogas plant in Poland.
 Installation in Skrzatusz is one of the very few biogas plants in Poland,
which currently do not generate losses because as a raw material for
biogas production uses only the waste, most of which gets for free.
 It was to be the first, pilot project of Zeneris company in the biogas
industry. The investor wanted to create its own design for the Polish
market, because the others offered a ready project brought in a briefcase
and not tailored to the needs of the real location.
 The owner of biogas plant in Skrzatusz applied another way to ensure its
cost-effectiveness. He built the plant for drying wood. Thus the heat
produced from biogas can be fully utilized.
 The biogas plant has its own biotechnological laboratory which makes
possible to test various raw materials and obtained data allows to
calculate how much of the substrate can be added.
Thank you for your attention !
Anna Pazera
Lodz University of Technology
[email protected]