Anaerobic Digestion and Biogas Use in the Great Lakes Region Food Industries Wisconsin Bioenergy Summit October 6, 2011 Joe Kramer
Energy Center of Wisconsin Madison, Wisconsin
Great Lakes Region Food Industry Biogas Casebook
Agricultural Utilization Research Institute
Project Funders WI Focus on Energy
NY State Energy Research & Development Authority
WI Milk Marketing Board Midwest Clean Energy Application Center
Center for Innovative Food Technology General Mills
Food Production Types Covered • Beer and beverages (2)
• Cheese (3)
• Meat (beef and pork) (2)
• Vegetables (1)
• Corn based snacks (1)
• Oats (1)
• Refrigerated dough products (1) • Sugar (1)
Why Choose Anaerobic Digestion? 1. Cost-effective treatment
Reduced energy needed Reduced biosolids
2. Produces renewable fuel 3. Can reduce odor from storage facilities
Anaerobic Digester Types Profiled Less complex
Covered lagoon (1) Mixed heated covered lagoon (1) Complete mix (2) Anaerobic contact process (3) Up-flow anaerobic sludge blanket (UASB) (4)
More complex
Mobilized film technology (1)
Digester Types Covered lagoon Mixed, heated covered lagoon
Graphic: Courtesy of US EPA AgSTAR Program.
City of Monmouth, IL, Pork Processing ■
Unheated covered lagoon (2000), HRT 7 days
■
Receives heated wastewater from hog production
■
Installed to reduce odors, provide pre-treatment
■
Exploring biogas use options
PHOTO: Courtesy of Cliff Haefke, US DOE Midwest Clean Energy Application Center.
Saputo Cheese USA Waupun, WI Mixed, heated, covered lagoon, (1991, 2009) HRT 5-6 days
>100k cfd biogas, scrubbed, fuels boiler for digester heat
Primary onsite treatment – after full treatment liquid is dischargeable Photo courtesy of Saputo USA Inc.
Digester Types (continued) Complete Mix (Continuous Mix)
Seneca Foods, Vegetable Processing Montgomery, MN Continuous mix, mesophilic, tank (2007), SF built, HRT 25-30 days
Pre-treatment of vegetable processing waste
Photo courtesy of Seneca Foods.
Seneca Foods (continued) Scrubbed, compressed, blended with NG Fuels process boiler and dryers in season
Fuels boiler in off season, hot water sent to 31 radiant heaters
Biogas displaces NG purchases Photos courtesy of Seneca Foods.
Digester Types (continued) Anaerobic contact process (ACP)
JBS Green Bay, Beef Production Green Bay, Wisconsin
Anaerobic contact process (1987), pre-treatment prior to city WWTP
HRT ~2 days AD gives JBS control over WW treatment costs
Picture: Courtesy of JBS Green Bay.
JBS Green Bay (continued) Biogas fuels 24.56MMBTU Cleaver Brooks boiler
Use of biogas offsets $600,000 per year in operating costs
Won 2005 WI Governor’s Award for Excellence in Environmental Performance Picture: Courtesy of JBS Green Bay.
Digester Types (continued) ■
Up-flow anaerobic sludge blanket (UASB)
Influent
Graphic: Courtesy of Doug Hamilton, Oklahoma State University
City of Beaver Dam, WWTP Cheese Production Beaver Dam, Wisconsin
Siemens Paques design, UASB (2011), ATI install, HRT 6 days
Will pre-treat waste from Kraft cream cheese production before city WWTP
City owns, Kraft will help finance w/fees Picture: Courtesy of Dennis Totzke, Applied Technologies Inc.
City of Beaver Dam WWTP (continued)
Electricity sold to Alliant Energy Heat used for influent WW and digester
Cost savings for all over alternatives Nearly cost-neutral for residents Photo: Courtesy of Wayne Karlovich, Applied Technologies, Inc.
City Brewery / Gundersen Lutheran ■
La Crosse, Wisconsin
■
Installed two Biothane UASB digesters (1982) for pre-treatment, HRT 4.4 hours
■
Gundersen Lutheran proposed to install generation (633kW)
■
GL sells electricity to Xcel Energy
■
CB uses heat on site Photo: Courtesy of Gundersen Lutheran.
AD Benefits Revisited
Reduced treatment costs
Companies “green” images
• Improved profitability • Aid job retention • Create new jobs • Boost local economies • Users of clean, renewable domestic energy • Good neighbors Photo: Courtesy of Dennis Totzke, Applied Technologies, Inc.
Contact Joe Kramer Energy Center of Wisconsin 455 Science Drive, Suite 200 Madison, Wisconsin 53711 608-238-8276x119 jkramer@ecw.org www.ecw.org/biogascasebook