REVISION 2.0 - APRIL 2017 CEDROB S.A. Turning wastewater into clean water & biogas CASE STUDY INSTALLATION FACTS • Customer: Cedrob S.A. • Industry: Poultry Slaughterhouse • Location: Ujazdówek (near Ciechanów), Poland • Design Flow: 5.720 m 3 wastewater per day (phase I: 3.000 m 3 /day, phase II: 2.720 m 3 /day) • Biogas: approx. 5.000-9.000 m 3 /d • Heat Energy: approx. 32.500 - 58.500 kWh/d SCOPE OF SUPPLY • Contract type: General Contractor (turnkey project). • Added value services: Design, project management and engineering, manufacturing, delivery, installation, commissioning, piping, electrical works and training on site, site engineering. • Wastewater solution phase I and II: : Filter system (2x NRF 90/300), Flocculator (2x PFR 140), Flotation (2x IPF180), denitrification, aeration tanks (BIOCTOR-CONTINUOUS), activated sludge flotation (4x GDF). • Biogas solution: Hydrolysis tank, digesters (4x AECOMIX TM -TAURUS), boiler, decanter centrifuges, gas scrubbers and flare. • Intelligent services: Service contract. • Official start date: Jan.2013 (phase I) and June 2016 (phase II). THE CLIENT Cedrob is a leader in meat processing and poultry production. The company has its own breeding farms, hatcheries, broiler breeding, poultry slaughterhouses and processing plants in Poland. THE BACKGROUND Cedrob strives to be energy-self-sufficient. Next to operating 2 slaughterhouses with a total capacity of 150.000.000 broilers and 900.000 geese per year, they are also hatching 160.000.000 eggs, and producing 720.000 tons of fodder per year. Nijhuis acted as total WWTP and biogas solution provider, taking care of technological & civil designs, equipment supply and installation & commissioning to realize the environmental ambitions of Cedrob. The WWTP is designed to treat different types of wastewater from Cedrob’s slaughterhouse in Ciechanow.
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REVISION 2.0 - APRIL 2017
CEDROB S.A.Turning wastewater into clean water & biogas
SCOPE OF SUPPLY• Contract type: General Contractor (turnkey project).• Added value services: Design, project management and engineering,
manufacturing, delivery, installation, commissioning, piping, electrical works and training on site, site engineering.
• Wastewater solution phase I and II: : Filter system (2x NRF 90/300), Flocculator (2x PFR 140), Flotation (2x IPF180), denitrification, aeration tanks (BIOCTOR-CONTINUOUS), activated sludge flotation (4x GDF).
• Biogas solution: Hydrolysis tank, digesters (4x AECOMIXTM-TAURUS), boiler, decanter centrifuges, gas scrubbers and flare.
• Intelligent services: Service contract.• Official start date: Jan.2013 (phase I) and June 2016 (phase II).
THE CLIENTCedrob is a leader in meat processing and poultry production. The company has its own breeding farms, hatcheries, broiler breeding, poultry slaughterhouses and processing plants in Poland.
THE BACKGROUNDCedrob strives to be energy-self-sufficient. Next to operating 2 slaughterhouses with a total capacity of 150.000.000 broilers and 900.000 geese per year, they are also hatching 160.000.000 eggs, and producing 720.000 tons of fodder per year.
Nijhuis acted as total WWTP and biogas solution provider, taking care of technological & civil designs, equipment supply and installation & commissioning to realize the environmental ambitions of Cedrob. The WWTP is designed to treat different types of wastewater from Cedrob’s slaughterhouse in Ciechanow.
Nijhuis Industries I www.nijhuisindustries.com
PROJECT CEDROB S.A. PHASE I
Site worksNovember 2012
Installation NFA-B November 2012
Finalizing digestersNovember 2012
Transportation
Site worksNovember 2012
Plant overviewNovember 2012
Electrical cabinets installationNovember 2012
Mixing system inside digesterNovember 2012
Nijhuis Industries I www.nijhuisindustries.com
PROJECT CEDROB S.A. PHASE II
Site worksNovember 2015
Site worksDecember 2016
Site worksJanuary 2016
Site worksJanuary 2016
Installation worksJune 2016
Installation worksJune 2016
Installation worksJuly 2016
Installation worksJuly 2016
Installation worksJune 2016
Installation worksJune 2016
Nijhuis Industries I www.nijhuisindustries.com
TURNKEY WWTP & BIOGAS SOLUTION
Biological Treatment
Biological Treatment
Activated sludge flotation units Activated sludge flotation units
Digester systems Gas scrubbers
Flotation unit
Nijhuis Industries I www.nijhuisindustries.com
FLOWCHART OF THE SYSTEM (PHASE I + II)
“Turn wastewater into clean water and biogas”
CUSTOMER BENEFITS1. Complete turnkey WWTP and biogas solution.2. Water quality to discharge to a near-by river.3. Turn wastewater into biogas4. Nijhuis expertise and application knowledge in
the poultry industry.5. Energy self-sufficiency, heat and electricity for
the WWTP, biogas plant and slaughterhouse.
Digester parameters & performances (approx.)
Excess sludge 81 m3/d
Flotation sludge 114 m3/d
Sludge from other plant 75 m3/d
Produced biogas 5.000-9000 m3/d(70% methane content)
Produced heat 32.500-58.500 kWh/d
Influent values (approx.)
COD 28.600 kg/day
BOD 14.300 kg/day
TSS 9.381 kg/day
TN 1.642 kg/day
TP 217 kg/day
Oil & Grease 1.436 kg/day
Effluent parameters
COD ≤ 125 mg/l
BOD ≤ 25 mg/l
TSS ≤ 35 mg/l
TN ≤ 30 mg/l
TP ≤ 3 mg/l
Oil & Grease ≤ 20 mg/l
Influent wastewater flow (approx.) - Phase I + II
Slaughtering 5.720 m3/day
Nijhuis Industries I www.nijhuisindustries.com
SOLUTIONThe WWTP is designed to treat different types of wastewater from Cedrob’s slaughterhouse, cutup line, cleaning water from the poultry farms and sanitary wastewater. The WWTP include a wide scope of Nijhuis technologies varying from filter systems (NRF 90/300), coagulation & flocculation (PFR 140), dissolved air flotation (IPF 180) and also an aerobic treatment system (BIOCTOR-CONTINUOUS) meeting all river water discharge standards.
The biogas plant is an integral part of the complete scheme. Biological excess sludge from the WWTP, sludge from primary Nijhuis DAF treatment, as well as sludge transported from off-site, are pre-treated and digested in the Nijhuis AECOMIXTM-TAURUS (2x 1.900 m3 and 2x 2.200m3 digesters volume). The digestate is dewatered with a decanter centrifuges.
The biogas produced in digesters is optimized by a desulphurization step inside digesters and enters then to 4 special gas scrubbers in order to obtain the high gas quality with a methane content of over 70%.
The plant commenced operating in January 2013 (phase I) and extended by phase II in June 2016.
“From cost to PROFIT”Cedrob Phase I and II
NIJHUIS AND CEDROB COOPERATIONIn 2009, Nijhuis won the contract to deliver a full-scale WWTP and biogas plant to Cedrob Phase I. In December 2014, Nijhuis was awarded the contract to build another wastewater and biogas plant for Cedrob S.A. (phase II), designed with a view on sustainable water use and resource recovery.
The installation is not only a WWTP. It is an example of turning the circular economy and profit center theories into reality.
Cedrob has chosen Nijhuis again because of our application knowledge and the trust and confidence built over years between both teams. Nijhuis delivered and installed a very flexible system to treat more than 5000 m3 per day.
CEDROB PHASE III Based on the professional cooperation and the results achieved, Cedrob has awarded the next 3rd extension to Nijhuis already. The order for the Phase III extension has been signed in 11.2016. Total system capacity to be reached is 9000 m3 / day of process wastewater and 500 m3 / day of rendering wastewater.
