The CHP system in Tymbark was launched in 2012. It produces electric heat energy, process steam and chilled water for the needs of the apple juice production.
The purpose of developing this system was to reduce the total demand for electricity and technological heat of the juice production plant through the use of biogas generated in the wastewater treatment plant (WWTP) and natural gas as the main fuel for electricity, process steam, chilled water and heating water production. In order to achieve the designated goal the Combined Heat and Power (CHP) system, based on the aggregate cogeneration with an electricity capacity of 1.0 MWe, fed with bi-fuel (biogas and high-methane natural gas).
The Tymbark plant has its own WWTP equipped with a biogas reactor in the anaerobic zone in which from the treated wastewater around 300 000 m3 of biogas is produced per year, which corresponds to the accumulated energy in the amount of approximately 2350 MWh.
In order to optimally use the total amount of biogas (35 m3/h) for energy purposes, there is a biogas tank included with a working capacity of 1500 m3, which stores produced biogas for 5-6 hours of cogeneration unit operation. In the remaining 18 hours of the day, the unit automatically switches to high-methane natural gas.
Heating water from the CHP cogeneration unit (80-92°C), is used as:
- for chilling water production in summer (temp. 7-12°C),
- to cover demand for heat energy and processing steam in winter.
Industrial symbiosis is also realized in Tybmark plant by treating external wastewater from Tymbark municipality and a local dairy plant OSM Limanowa.
- Wastewater inflow (industrial and/or municipal)
- Biogas reactor
- Combined Heat and Power Unit
Evidence of success
- About 25% of Tymbark juice production plant energy demand is covered from on-site produced biogas.
- Symbiosis between Tymbark juice producing plant, Tymbark municipality and a local dairy plant OSM Limanowa in terms of wastewater treatment.
Potential for learning or transfer
The good practice is considered to have a strong potential for transfer to other regions due to a long list of similarities in the technological processes used in the food processing plant all over the world. High load of organic matter in the sewage from fruit processing gives the opportunity to capture the biogas from the anaerobic wastewater bioreactor.
For example, the studied case from Tymbark which mainly produce apple and black current juice has to manage with similar problems with waste and wastewater treatment as an orange juice producing plant in southern Europe countries or a strawberry jam processing plant in other countries
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