Periodic Reporting for period 2 - PigHeat (Utilizing Pig By-products as Heat Source to Save Recycling and Energy Cost.)
Reporting period: 2017-10-01 to 2018-08-31
The objectives of the PIGHEAT project, arise from the requirement received by several slaughterhouses in the area of Girona-Spain, where our factory is located, in the sense that they wanted to find a solution to the costs generated by pig hair, both at the economic and environmental level.
Trying to give an answer to this request, we began to think about different possibilities, initially based on the main characteristic of hair and its high percentage of protein in its composition. We quickly realized the few possibilities offered, taking into account the strict regime of possibilities that the regulations in force about the treatment of animal by-products allow. Therefore, we thought that if we managed to transform pig hair into fuel, its value would become that of the fuel that we substituted. Based on this idea, we set the following objectives:
a) To demonstrate that pig hair could be transformed into fuel on an industrial scale, and that its production presented no problems.
b) To prove that the heating power of the fuel is high.
c) To prove that the fuel burned correctly in an industrial steam generator, and that the combustion presented no later problems.
d) To prove that the levels of emissions resulting from the combustion were within the parameters required by the regulations in force throughout the EU (some of the most demanding worldwide).
e) To prove that the production of this fuel was economically viable, amortizable within a reasonable period of time.
Trying to give an answer to this request, we began to think about different possibilities, initially based on the main characteristic of hair and its high percentage of protein in its composition. We quickly realized the few possibilities offered, taking into account the strict regime of possibilities that the regulations in force about the treatment of animal by-products allow. Therefore, we thought that if we managed to transform pig hair into fuel, its value would become that of the fuel that we substituted. Based on this idea, we set the following objectives:
a) To demonstrate that pig hair could be transformed into fuel on an industrial scale, and that its production presented no problems.
b) To prove that the heating power of the fuel is high.
c) To prove that the fuel burned correctly in an industrial steam generator, and that the combustion presented no later problems.
d) To prove that the levels of emissions resulting from the combustion were within the parameters required by the regulations in force throughout the EU (some of the most demanding worldwide).
e) To prove that the production of this fuel was economically viable, amortizable within a reasonable period of time.
The works performed once the slaughterhouse was selected, were to design the equipment where the process of transforming the hair into fuel would be carried out, since it should be adapted to the real needs of slaughterhouse. Then we had to perform the same tasks in the steam generator, hair storage hopper and fuel storage tanks.
Once the main elements of the installation were designed and dimensioned, and taking into account where we should locate the equipment, we began to design the layout of the installation. Finally, we installed lines of fluids and machines according to the planning made. The results obtained were the following, based on the objectives set:
A) Objective nº 1. To demonstrate that pig hair could be transformed into fuel on an industrial scale, and that its production presented no problems. Once the installation was finished, and all the relevant tests were carried out, the first of the tests was done with half load. With the experience we had in the laboratory, we performed the same type of process, and fortunately the result was identical. A dry fuel, and as we could see later, of high calorific value was obtained.
B) Objective nº 2. To prove that the heating power of the fuel is high. With the first samples, the Univeristy of Vic came on the scene. Being able to check the calorific value of the product obtained was very important. The results obtained in the laboratory of the University of Vic were satisfactory. The calorific value was 4300 Kcal/Kg, a really high value!
c) Objective nº3. To prove that the fuel burned correctly in an industrial steam generator, and that the combustion presented no later problems. We proceeded with the first combustion tests. As a preliminary step, and in order to safeguard the fuel obtained, we loaded the biomass silo with wood chips, which led us to test the entire truck unloading system too. We wanted to make the appropriate adjustments in the steam boiler itself. We had to test the equipment, and for that we carried out the combustion and preheating tests of the firebox with biomass, to have everything ready to be able to focus on the tests with pig hair.
Once the parameters were achieved and adjusted properly, we could go in search of checking if we could meet this third objective. The tests were performed with the fuel and biomass. Once these tests were finished we look at the tubular plate and the mobile grills, without any sign of ashes stuck.
D) Objective nº 4. To prove that levels of emissions resulting from the combustion were within the parameters required by the regulations in force throughout the EU (some of the most demanding worldwide). Scientists from the University of Vic visited the installation, this time accompanied by a specialist in measurement of combustion gases. The measurements had to be taken under optimal working conditions. Prior to the measurement there had been a meeting between the University of Vic and our technicians, in order to analyse the requirements of the regulations in force, and decide which parameters should be measured. Once the tests were over we were able to receive the complete report, the results were unbeatable. The goal was fulfilled.
E) Objective nº 5. To prove that the production of this fuel was economically viable, amortizable within a reasonable period of time. The use of PIGHEAT technology does not increase the energy cost of the slaughterhouse operation, but rather the opposite: It saves the costs of hair collection as a by-product by an external company, and provides the industry with more energy than needed to process it. It also reduces the carbon footprint, since it eliminates the amount of fossil fuels that these companies consume. Also using, as has been developed in the pilot plant, an exchanger that recovers the latent heat of the evaporated water from the hair, the energy saving is even greater.
After the tests, we calculated that the payback period for a standard plant for such capacity would be in the worst case 6.3 years (gas) and less than 3.6 years for light oil. With these results we are satisfied. We have achieved all the objectives that we had initially set ourselves, and we have demonstrated what at the laboratory level convinced us and the European Commission two years ago, and that served us to be worthy of receiving their trust. Pig hair, which until now was a waste without any value, can already be considered one of the main assets of slaughterhouses, and will no longer represent an environmental problem.
Once the main elements of the installation were designed and dimensioned, and taking into account where we should locate the equipment, we began to design the layout of the installation. Finally, we installed lines of fluids and machines according to the planning made. The results obtained were the following, based on the objectives set:
A) Objective nº 1. To demonstrate that pig hair could be transformed into fuel on an industrial scale, and that its production presented no problems. Once the installation was finished, and all the relevant tests were carried out, the first of the tests was done with half load. With the experience we had in the laboratory, we performed the same type of process, and fortunately the result was identical. A dry fuel, and as we could see later, of high calorific value was obtained.
B) Objective nº 2. To prove that the heating power of the fuel is high. With the first samples, the Univeristy of Vic came on the scene. Being able to check the calorific value of the product obtained was very important. The results obtained in the laboratory of the University of Vic were satisfactory. The calorific value was 4300 Kcal/Kg, a really high value!
c) Objective nº3. To prove that the fuel burned correctly in an industrial steam generator, and that the combustion presented no later problems. We proceeded with the first combustion tests. As a preliminary step, and in order to safeguard the fuel obtained, we loaded the biomass silo with wood chips, which led us to test the entire truck unloading system too. We wanted to make the appropriate adjustments in the steam boiler itself. We had to test the equipment, and for that we carried out the combustion and preheating tests of the firebox with biomass, to have everything ready to be able to focus on the tests with pig hair.
Once the parameters were achieved and adjusted properly, we could go in search of checking if we could meet this third objective. The tests were performed with the fuel and biomass. Once these tests were finished we look at the tubular plate and the mobile grills, without any sign of ashes stuck.
D) Objective nº 4. To prove that levels of emissions resulting from the combustion were within the parameters required by the regulations in force throughout the EU (some of the most demanding worldwide). Scientists from the University of Vic visited the installation, this time accompanied by a specialist in measurement of combustion gases. The measurements had to be taken under optimal working conditions. Prior to the measurement there had been a meeting between the University of Vic and our technicians, in order to analyse the requirements of the regulations in force, and decide which parameters should be measured. Once the tests were over we were able to receive the complete report, the results were unbeatable. The goal was fulfilled.
E) Objective nº 5. To prove that the production of this fuel was economically viable, amortizable within a reasonable period of time. The use of PIGHEAT technology does not increase the energy cost of the slaughterhouse operation, but rather the opposite: It saves the costs of hair collection as a by-product by an external company, and provides the industry with more energy than needed to process it. It also reduces the carbon footprint, since it eliminates the amount of fossil fuels that these companies consume. Also using, as has been developed in the pilot plant, an exchanger that recovers the latent heat of the evaporated water from the hair, the energy saving is even greater.
After the tests, we calculated that the payback period for a standard plant for such capacity would be in the worst case 6.3 years (gas) and less than 3.6 years for light oil. With these results we are satisfied. We have achieved all the objectives that we had initially set ourselves, and we have demonstrated what at the laboratory level convinced us and the European Commission two years ago, and that served us to be worthy of receiving their trust. Pig hair, which until now was a waste without any value, can already be considered one of the main assets of slaughterhouses, and will no longer represent an environmental problem.
The progress that the PIGHEAT technology provides represents an important step forward in reducing the carbon footprint of slaughterhouses of pigs (large consumers of energy), decreases their energy costs, eliminates a highly perishable waste and therefore the contamination of aquifers by the great volume of water that it contains, and avoids the contamination that the constant route of trucks for its collection supposes.
We hope that we will be able to transmit to the slaughterhouses all these advantages and the great potential PIGHEAT offers to the 21st century slaughterhouses, and that this work will be reversed to improve the image that society as a whole has of pig slaughterhouses, and also to reduce the price of meat in the markets.
The social impact that we have obtained at the moment has been very satisfactory, based on the reactions that the slaughterhouse managers have shown us, as we have been contacting them, as well as the distribution companies of equipment in these industries, which are the type of companies in which we rely on to carry out our commercial activity outside Spain.
We hope that we will be able to transmit to the slaughterhouses all these advantages and the great potential PIGHEAT offers to the 21st century slaughterhouses, and that this work will be reversed to improve the image that society as a whole has of pig slaughterhouses, and also to reduce the price of meat in the markets.
The social impact that we have obtained at the moment has been very satisfactory, based on the reactions that the slaughterhouse managers have shown us, as we have been contacting them, as well as the distribution companies of equipment in these industries, which are the type of companies in which we rely on to carry out our commercial activity outside Spain.