(Aurea 2010) NOMINEE 05: Alltech-Fermin - unit that converts biological waste into biogas

Alltech-Fermin, regional leader in production of yeast and other yeast-based products, put in operation the unit for treatment of waste water from that factory in December 2009, in which over EUR 9m were invested. What makes the unit in Senta different from others of the kind is the fact that biogas in that unit is used for combined generation of both heating and electric energy for the industrial complex.

INNOVATION

The innovation of Alltech-Fermin's unit lies in application of anaerobic and aerobic treatment of waste water instead of classical technology of nitrification and denitrification. Therefore, biological waste is turned into biogas, which is then used for production of electric energy. Production, filtering, drying and burning of biogas in this unit cut gas consumption by up to 37% and electricity consumption by up to 34%. Along with electricity and gas, hot water that is produced during the work of the unit for combined production is used for heating various processes in the unit.

This is an example of application of innovative, economically and energy efficient technology "Demon". The unit is designed to clean heavy waste water (458,000 ES) created during the process of production of baking yeast until it reaches parameters that are defined by the authorized organs.

The unit includes three basic waste water treatments:

- Anaerobic filtering procedure - optimal setting of parameters of waste water and fermentation in highly efficient EGSB anaerobic reactors

- Aerobic filtering procedure - economic elimination of ammonia from waste water - reaction in "demon" pools; biological treatment of waste water - SBR pools as biological barrier for releasing carbon and nitrogen with the aim of reaching given parameters of waste water

- Chemical-physical treatment of waste water - elimination of excessive phosphorus and fine suspended matters before releasing treated water into water current;

The supplier of technical-technological solution is German company Hager+Elsaesser from Stuttgart.

(Photo: alltech fermin)

SOCIAL UTILITY

Conversion of biological waste satisfy the needs of waste water treatment units for fuel while saving natural resources, preventing both environment pollution and emission of methane into atmosphere and maximally preferring the Kyoto Protocol.

Introduction of a modern unit for treatment of heavy industrial waste water will reduce the pollution of the water resources of the Tisa river and the quantity of released mud. The project will result in smaller emission of methane and unpleasant smells, lower vector of infection and bacteria, and it will lead to better sanitarian terms in local quality of life. The use of biogas, produced during the anaerobic waste water treatment, as a source of energy in cogeneration units will reduce the dependence on fossil fuels and lead to greater application of the sources of renewable energy. The project will set a valuable example for the industry that is interested in similar waste water treatment units. In this way, public awareness of waste water management and generation of renewable energy will be raised to a higher level. Through application of the state-of-the-arts technology of waste water treatment and training of local manpower, the project will contribute to the transfer of technology and the transfer of appropriate skills and knowledge, respectively. The project will also create new jobs.

Alltech-Fermin's unit, designed by Hager + Elsässer, combines anaerobic and aerobic procedures of waste water treatment.

(Photo: alltech fermin)

COMMERCIAL SUCCESS

The produced biogas is burnt in gas cogeneration units (electric power capacity is 2 x 703 kW). The work of the cogeneration unit generates electric energy and heat that is partially needed for maintenance of mesophilic process of digestion, while both forms of energy are available to the connected production in factory Alltech-Fermin, which will positively affect the financial balance of primary production of baking yeast (the level of energy efficiency of cogeneration units exceeds 90%). Also, by putting the new unit in operation, the company met technical conditions for acquiring the status of Authorized manufacturer of electric energy and use of stimulus measures in accordance with the Regulations governing the stimulus measures for production of electric energy by means of use of renewable energy sources and combined production of electric and heating energy.

The nomination for 2010 Aurea award is backed by insurance company Wiener Städtische.