THE BIOGAS PLANT AT BALLYTOBIN Site: The Camphill Community, Ballytobin, Callan, County Kilkenny, Ireland Start-up date: December 1999 Owner: Bio-Energy & Organic Fertiliser Services (BEOFS) – a company established by the Camphill Community to design, build and operate the biogas plant. SUMMARY In this small-scale centralised anaerobic digestion plant, slurry collected from local farms is co-digested with kitchen refuse and food-industry wastes brought from as far as Dublin and Cork; the biogas produced fuels a small district heating system. The liquid digestate is returned to the farmers as fertiliser, and the solid residues are composted for use as soil conditioner. AIMS of the PROJECT To satisfy the energy requirements of a small community whilst making a positive environmental impact. To demonstrate centralised anaerobic digestion for the first time in Ireland. To create work opportunities for persons needing a supportive work environment. BACKGROUND Founded in Scotland by some refugees from Nazi-occupied Austria, the Camphill movement cares for young persons with special needs. At the Camphill Community in Ballytobin between 80 and 100 people with multiple disabilities and their volunteer helpers live, learn, work and relax in a traditional farmhouse and in modern purpose-built accommodation. There are classrooms, art and craft workshops, and a large hall used for community activities, religious services, local events and seminars. About eleven hectares of land are used for grazing and gardening. The community farms organically and is strongly committed to caring for the environment, and Ireland's first Centralised Anaerobic Digestion plant was commissioned here in 1999. The "Genesis Project" was encouraged and actively supported by Kilkenny County Council, Tipperary Rural Business Development Institute, FAS, and the Barrow-Nore-Suir Development Board; technical assistance came from UCG Environmental Science Section, Teagasc, and SolEarth Architects, of Dublin. DESCRIPTION A novel arrangement of two digesters operating in series forms the core of the installation. Food waste (mixed with some slurry to increase fluidity if necessary) is fed into one end of a 150m3 horizontal steel 'plug-flow' reactor along which it is slowly moved by a rotating spiral impeller, reaching the discharge point after about 20 days. The contents are maintained at a temperature of 55oC, resulting in the destruction of most pathogens and parasites. (New regulations will require a pre-treatment stage where the food waste is heated at 70OC for one hour before digestion, to ensure complete sterilisation). The partially digested material displaced from the plug-flow digester together with undigested slurry is pumped into the second 'stirred' digester; this is a 450 m3 tank covered by a flexible double membrane which acts as a gasholder to accommodate small fluctuations in gas production and demand. In this vessel digestion takes place at 37OC, and retention time is about 30 days. Spent liquor leaving the second digester is separated into solid and liquid phases, the liquid being returned without charge to the farms where it is spread as fertiliser, and the solids are composted and air-dried for sale or use on-site as a peat-free soil conditioner. About 14 tonnes of slurry are collected free from four local farms every day. On average 6 to 8 tonnes of kitchen and food-industry wastes are also received daily, and 'gate fees' are charged to the waste management companies concerned. Periodically sludge removed from the community's sewage settlement tanks is also digested (the filtrate from these tanks passes into reed-beds for neutralisation). Biogas production is estimated at 600m3 per day, and it is utilised in either an 85kW or a 200kW hot water boiler to supply the community district heating system, and also in a second 85 kW boiler which heats the digesters. A gas engine and 105 kVA generator set with combined-heat-and-power capability is installed. Unfortunately, BEOFS was not successful in obtaining a contract under recent AER rounds, and the unit is retained only as an emergency standby generator; consequently, about 100m3 of surplus gas has to be flared daily during the summer months. INVESTMENTS & FINANCING Support for the capital cost of the initial phase of construction was received from the Rural Development Programme, and for the second phase from the European 'Leader Programme II'. A grant towards non-capital costs (design, project management, etc.) came from the European 'Horizon' scheme, supporting projects creating employment for persons with disabilities. As a demonstration project, funding for dissemination of information (including a seminar held on-site in June 2000) came from the EU 'Altener' programme. Four persons are employed full-time in operating and maintaining the biogas plant, collecting slurry, delivering digestate, and processing compost; residents of the community assist as required. The wages of the manager (who is a qualified gasfitter) and one labourer are met entirely from revenues ( mainly gate fees), whilst those of two other local persons are subsidised by a social employment scheme. RESULTS & ENVIRONMENTAL IMPACT Energy content of the biogas produced is circa 5 000 GJ (gross CV) per annum; some 500 GJ is lost in flared surplus gas, and an estimated 2 000 GJ per year is used for digester heating, so that net annual energy production is about 2 500 GJ. Used in the district heating boilers, this energy displaces approximately 55 000 litres of gas-oil, avoiding the emission of 165 tonnes of carbon dioxide of fossil-fuel origin every year. The destruction of many pathogens and parasites reduces the risk of diseases being passed between animals, and between animals and humans. Weed seeds are also killed. The separated liquid digestate contains less than 5% solid matter and is easily spread using simple spraying techniques; containing most of the nitrogen, phosphorus and potassium of the original slurry, it is rapidly absorbed in to the soil (minimising run-off into watercourses) and is readily taken up by plants. The liquid is practically odourless, obviating the unpleasant smells associated with spreading raw manure. LESSONS LEARNED Centralised co-digestion of farm slurry with mixed food wastes has been successfully demonstrated. Rigorous monitoring of food wastes has proven necessary to ensure that digestion is not inhibited e.g. by adverse pH values. Maintenance of the plug-flow digester has proven more difficult than with the stirred reactor, due to the need to empty the vessel to effect any repairs to the impeller. REPLICABILITY This small, centralised biogas plant might be replicated wherever a sufficient local demand for heat exists (e.g. residential communities, swimming pools & leisure centres, or rural industrial operations). Co-digestion of manure with other organic materials enhances gas production, and the acceptance of such wastes from waste management companies would provide additional revenues. The relatively small size of Irish farms imposes economic and logistical difficulties in collecting large amounts of slurry, so inhibiting the development of large scale centralised digesters. Except where there is a local requirement for large amounts of heat or there is a potential purchaser of a medium grade gaseous fuel (such as a brickworks), such plants would have to operate as combined heat-&-power generators and maximise their sales of electricity. MAIN MANUFACTURER & SUPPLIER Biogas Nord of Germany designed and constructed the plant. Biogas Nord GmbH Kreuzstrasse 12 D – 33602 Bielefeld Germany tel: +49 521 55 44 fax: +49 521 48 www.biogas-nord.de MORE INFORMATION Further information may be obtained from -Mark Dwan Camphill Community Ballytobin Callan Co. Kilkenny Ireland tel: +353 (0)56 25114 fax: +353 (0)56 25849 markdwan@ballytobin.ie