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A Year in the Life of BV Dairy’s AD Plant

A Year in the Life of BV Dairy’s AD Plant. AD Update. AD plant signed over March 2011 All waste produced at the manufacturing plant is treated by the AD plant Award winning. kWh Electricity Generation. 176. 27%. Challenges. Running at 45% capacity

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A Year in the Life of BV Dairy’s AD Plant

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  1. A Year in the Life of BV Dairy’s AD Plant

  2. AD Update • AD plant signed over March 2011 • All waste produced at the manufacturing plant is treated by the AD plant • Award winning

  3. kWh Electricity Generation 176 27%

  4. Challenges • Running at 45% capacity • PAS 110 certification, and Biofertiliser properties • Solids Separation Unit

  5. What went wrong at the AD Plant??

  6. After a night out on the town

  7. We woke up to this

  8. So, what was the cause? What should happen: • Gas is stored within the dome • Once the dome reaches a given level, gas is ejected to CHP engine, Flare or Boiler • If gas pressure within dome increases, the gas will be emitted via the Pressure Relief Valve (PRV)

  9. So, what was the cause? What actually happen: • Sludge entered the gas line blocking the path to the CHP/Flare • The PRV failed • Gas was unable to exit the dome which resulted in a pressure build up

  10. The outcome of the AD Failure • One word….EXPENSIVE • All waste/permeate produced from BV Dairy had to be sent off-site • Digestate had to be removed as Hazardous waste, as an instant reaction • Increase in waste water treatment • Loss of potential electricity generation • Increased OPRA Scores • Interestingly despite the initial gas release we didn’t have a single complaint from our neighbours

  11. The Repair • Two new dome membranes had to be manufactured, which had a 1 ½ month lead time • The PRV was replaced with an improved design • Alarms are now in place to alert engineers of the presence of sludge within the catchment pot

  12. Current Situation • The digester coped with being dormant for two months, with methane being produced within two days of the repair • Due to strong back up and understanding from the EA and Wessex water we managed to minimise damage to the environment • Current issues with Digestate disposal and low volumes of incoming waste, The Government needs to look at positioning of AD Plants in the UK

  13. What’s next?!RHI and water saving 5oC 30oC 85oC 15oC

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