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Great Lakes Water Conservation Conference for craft brewers and cheese makers October 18, 2010 CLEAR HORIZONS, LLC. PEACE OF MIND THROUGH ORGANIC WASTE MANAGEMENT SOLUTIONS Vision As a leading provider of Biogas Energy Systems in Wisconsin with a reputation for quality and reliability in all transactions, Clear Horizons intends to leave the Earth a better place than we found it. June 2, 2009 Summary • • • • • • Clear Horizons Background Anaerobic Digestion How to Develop a Project How Can I Do It? Case studies Questions during open discussion or at cocktails. Clear Horizons LLC PPC Partners, Inc. Pieper Electric MetroPower Clear Horizons MP Systems Servicing The Midwest & Southeastern U.S. One of the Nations Largest Electrical/Mechanical Contractors Privately Held/Employee Owned 1,207 Employees - 14 States $205 Million in Revenue Clear Horizons • Developed out of the Water/Wastewaster Division of Pieper Electric – Pieper Electric has been in Wastewater for over 30 years – Used its knowledge in building municipal systems to develop Clear Horizons • Strategic Partner McMahon (Neenah, WI) – Provides engineering services for projects – Assists in Feasibility Studies • Team with Engineering firms with expertise with certain clients or industries. – Ex. Procorp Enterprises (Milwaukee, WI) in cheese plants Digester System Flow Diagram Anaerobic Digestion Process What is it? • Anaerobic – without oxygen • Digestion – the process by which organic matter in sludge is decomposed with the release of a burnable mixture of gases • Naturally occurring biological process – Stomach – Bottom part of lagoon Anaerobic Digestion Process How does it work? • Sequential stages of breaking down organic matter by different types of bacteria • Hydrolytic and fermentative bacteria covert fats, proteins, and carbohydrates to fatty acids, alcohol, carbon dioxide, hydrogen, ammonia, and sulfides • Acetogenic bacteria (acid forming bacteria) convert products of previous stage to acetic acid, hydrogen, and carbon dioxide • Methanogenic bacteria (methane forming bacteria) covert products of previous stage to biogas – Biogas is approx 50-70% CH4(methane), 30-50% CO2(carbon dioxide), trace amounts of H2S(hydrogen sulfide) Anaerobic Digestion Process How does it work? • Biogas is created which contains about 55% methane, 40% Carbon Dioxide, 5% other • Growth of bacteria is optimized at higher temperatures • Mesophilic – 90-100º F • Thermophilic – 130-140º F Anaerobic Digestion System What is it? • Anaerobic Digestion System attempts to control process and capture biogas • Utilize biogas to power an engine/generator • Waste heat from engine is used to provide heat to system and farm for hot water, milk pasteurization, and in floor heat in winter. Digester System Complete Mix or other technologies • Mesophilic • Above ground stainless steel bolted tank(s) • Agitation inside tank to continually mix • Most common type of system in Europe • Typically prefer 5-10% solids • Retention times of 30-40 days • Bed reactors, Fixed Film, Lagoons IMPORTANT What goes into an anaerobic digester comes out of a digester. Nutrients, nor volume, are destroyed or removed! How to Develop a Project? 1. Get educated at conferences and classes and contact local or Federal agencies such as Dept of Energy and USDA. (Bring your banker!) 2. Understand what you have and what you need and want. What are your organic waste streams? What is the cost of handling, disposal? Seasonal fluctuations, future plans? What do you want to achieve? $, bedding, reduced volume, odor, etc….. 3. Contact a qualified engineer or digester designer and start building a team. What is their track record? 4. Conduct initial feasibility to answer “Is this something even worth investigating?” Little to no cost, just time. If yes……. 5. Conduct formal feasibility study. $5,000$75,000. Focus on Energy in WI pays part of. 6. Understand economics of project. What do you value things like odor or “being green”? Can you actually make money? Few do at current biogas buyback rates. 7. Work with developer/designer to apply for grants and select equipment and suppliers, sign contracts. 8. Build project (not in winter in WI). If AD is desired, how can I do it? Money Invested $,$,$,$,$ Return $,$,$,$,$ • Let someone else do it. Deliver waste to someone else, let them process and dispose. – Municipal treatment. 0-$, 0 – Farm with manure and land application. 0-$,0 – Disposal company. 0-$,0 • • • • Third party ownership at your plant. $, $ Form a unique partnership. $$$, $$$ Partner for community approach. $$$$,$$$$ Do it yourself at your plant. $$$$$,$$$$? Crave Brothers Farm, Crave Brothers Farmstead Cheese Waterloo, WI 633 kW Gundersen Lutheran, City Brewery LaCrosse, WI BioCycle December 2009, Vol. 50, No. 12, p. 42 633 kW Clear Horizons-Dane Dane, WI 2,000 kW Operational spring 2011 Partners • • • • • • Endres Dairy Ripp’s Dairy Valley White Gold Dairy Future Farmers Dane County Local suppliers of FOG’s (fats, oils, grease) Mont Chevre-Betin Belmont, WI 335 kW Photo taken from Mont Chevre Biogas Plant City of Belmont WWTP Mont Chevre Manufacturing facility Team • Mont Chevre-Owner • Procorp Enterprises-Engineer • Clear Horizons-Construction Management, Electrical, Automation & Controls, CHP • Belmont Municipal Waste Water Treatment Plant • Local subcontractors • Dept of Energy, Focus on Energy Quote In regards to receiving a $550,000 low interest loan from WI Dept of Energy, Mont Chevre’s president, Arnaud Solandt said he appreciated the state support for “private projects like ours that build environmentally-sound solutions to manufacturing. The loan will allow us to expand further and create new jobs within the community.” Thank You Karl Crave www.clearhorizonsllc.com [email protected]