An introduction to developing and operating anaerobic digestion facilities in the UK

The Practical
Guide to AD
First Edition

Sponsored by

Sponsored by

Welcome

Supporting the
growth in AD
Welcome to the first edition of The Practical Guide to AD, an all-encompassing
introductory reference tool for those developing and operating anaerobic digestion
facilities in the UK. Whether you have a basic understanding or in-depth technical
knowledge of the industry, this handbook is designed as a hands-on guide to help you
with every stage of your project.

Editorial team
Editor
Kirsty Sharpe
Features Editor
Kate OReilly
Chief Executive
Charlotte Morton
Policy Manager
Matt Hindle
Commercial Director
Louise Wallace
Technical Editor
Zo Lenkiewicz
Sales Manager
Jamil Ahad

With more than 40 contributors, a team of reviewers and external stakeholders feeding-in their expertise and
knowledge, this reference tool is produced by the industry for the industry. It is intended to be a high-level
living document and one which we hope will become a vital resource for all those involved in the AD and
biogas industry.
My special thanks go to all the contributors, ADBA members and the editorial team who have helped put
together this first issue of The Practical Guide to AD; it has required a lot of hard work, perseverance
and dedication. Particular thanks, too, to Terry Brownhill for kick starting the guide in the first place and
tirelessly supporting the project at every stage. Also, a big thanks go to the sponsors of this edition whose
support allowed us to cover a large proportion of the production costs enabling us to offer the publication
to members free of charge and to non-members at a reduced rate.
I hope you find the information in the guide useful and that it will help support the development and operation
of AD plants across the UK. Please do not hesitate to contact us with any comments or suggestions for the
next updated issue which will be published in 2014.
Best wishes,

Charlotte Morton,
Chief Executive, ADBA

Contact us:

Canterbury Court,
Kennington Park Business Centre,
1-3 Brixton Road, London, SW9 6DE
T+44 (0)203 176 0503
E [email protected]
W www.adbiogas.co.uk
Follow us on Twitter: @adbiogas

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The practical guide to AD

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Contents
1 WHAT IS ANAEROBIC DIGESTION?

11

1.1

What is anaerobic digestion?

12

1.2

The AD process

13

1.3

AD a proven technology

14

2 WHY Anaerobic digestion?

17

2.1

Introduction

18

2.2
2.2.1
2.2.2
2.2.3
2.2.4

AD benefits everyone
Benefits to farming
Benefits to the public
Benefits to local authorities and government
Benefits to business

18
18
19
19
19

2.3
Financial incentives
2.3.1
The Renewables Obligation (RO) and Feed-in Tariff (FIT)
2.3.2
Levy Exemption Certificates (LECs)
2.3.3 Heat from biogas combustion: renewable heat
incentive (RHI)
2.3.4 Biomethane grid injection: renewable heat
incentive (RHI)
2.3.5 Biomethane as a transport fuel: Renewables
Transport Fuels Obligation (RTFO)

19
20
20

2.4

Government policy

21

FEEDSTOCKs

23

3.1
3.1.1
3.1.2
3.1.3

Introduction to feedstock
Composition
Sourcing feedstock
PAS 110

24
24
24
25

3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7

Feedstock by sector
Agricultural animal waste
Agricultural plant based
Food waste post-manufacture
Organic commercial and industrial waste
Household food waste
Woody materials and green waste
Sewage and wastewater sludge

25
25
26
26
27
27
27
28

3.3
3.3.1
3.3.2
3.3.3
3.3.4

3.3.5
3.3.6

Feedstock treatment and ABPR requirements

Pre-treatment processes
Animal by-products
Hub and Pod Digestion and ABPR
AD processes compared to pasteurisation
requirements
Feedstock pre-treatment systems (generic) for AD
Category 2 treatment rendering animal wastes

28
28
29
31

The practical guide to AD

20
20
21

31
32
34

3.4
3.4.1
3.4.2
3.4.3
3.4.4

Handling of feedstock general requirements

Storage of feedstock
Parasites and pathogens in feedstock
Transferring waste to the digestion plant
Cost considerations

35
35
36
36
36

The ANAEROBIC DIGESTION Process

39

4.1
4.1.1
4.1.2
4.1.3
4.1.4

Characteristics of AD systems
Operating temperature
Digester feed
Loading rate
Hydraulic retention

40
40
40
40
40

4.2
4.2.1
4.2.2
4.2.3

Configuration
Liquid digestion configurations
Wet digestion configurations
Dry digestion configurations

41
41
41
42

4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
4.3.10
4.3.11
4.3.12
4.3.13
4.3.14
4.3.15

Operational considerations wet digestion

Screening and depackaging
Grit
Gas system design
Operating pressure
Purging
Hydrogen sulphide in biogas
Design of slurry pipework
Heating
Mixing
Rheology
Types of wet digester mixing
Whole digestate storage
Dewatering
Odour
Foaming

43
43
44
44
45
45
46
46
46
47
47
48
50
50
51
51

4.4
4.4.1
4.4.2
4.4.3

Operational considerations dry digestion

General considerations with dry digestion
Plugflow systems
Static dry AD systems

52
52
52
55

4.5
4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
4.5.7
4.5.8

Digester monitoring
pH
Carbon:nitrogen (C:N) ratio
Methane concentration
Volatile fatty acids
Alkalinity buffer
Ammonia concentrations
Trace elements
Retention time in digester

56
56
57
57
57
57
57
57
57

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Contents

5 producing and using BIOGAS

59

6 DIGESTATE

81

5.1

Benefits of biogas

60

6.1

Introduction

82

5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5

Biogas composition
Methane
Water
Hydrogen sulphide
Oxygen
Ammonia

60
60
60
60
61
61

6.2

Benefits of digestate for agricultural land

83

6.3
6.3.1
6.3.2
6.3.3
6.3.4

Separating the digestate

Whole digestate
Liquor
Fibre
Cake

83
84
84
85
85

5.3
5.3.1

Variations in biogas composition

Factors affecting biogas yield

61
63

5.4
5.4.1
5.4.2

Biogas cleaning prior to use

Hydrogen sulphide removal
Siloxane (silicon oxygen methane) removal

63
64
64

5.5
5.5.1
5.5.2

Biogas monitoring
Which gases need to be monitored and why?
How is biogas monitored?

65
65
65

6.4
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7

Separation techniques
Screw press
Belt press
Centrifuge
Bio-drying
Evaporation
Membrane filtration and reverse osmosis
Chemical separation

85
86
86
86
86
86
86
86

5.6

Introduction to using biogas

65

5.7

Combustion to generate heat only

66

5.8
5.8.1
5.8.2
5.8.3
5.8.4
5.8.5
5.8.6

Combined heat and power (CHP)

Power generation
Parasitic power
Heat use
Jacket cooling water
Flue gas heat recovery
Steam generation

66
66
66
67
68
68
68

6.5
6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
6.5.6
6.5.7

Application of digestate
Bandspreading
Tankering
Trailing shoe
Dribble bars
Disc injectors
Tine injectors
Manure-type spreaders

86
87
87
87
87
87
87
87

5.9
5.9.1
5.9.2
5.9.3
5.9.4

Combined heat, power and cooling

Generating additional electricity from waste heat
Gas engine availability
Maintenance contracts versus independent service
Electricity connection

68
69
70
71
71

6.6
6.6.1
6.6.2
6.6.3
6.6.4

Variations in digestate with sector

Digestate from farm slurries and crops
Digestate from the water industry
Digestate from source-segregated waste
Digestate from mixed waste

87
88
88
89
90

5.10
5.10.1
5.10.2
5.10.3
5.10.4

Biomethane
Upgrading biogas to biomethane
Injecting biomethane to the grid
Gas quality monitoring and energy metering
Biomethane market

71
71
73
74
75

6.7
6.7.1
6.7.2
6.7.3

Storage and transport

Storing liquid digestate
Storing dewatered digestate
Transporting digestate

90
90
90
90

PLANNING

93

7.1

Is planning permission required?

94

5.11

Biogas as a vehicle fuel

76

5.12

Future trends

77

7.2
Progressing a planning application
7.2.1 Pre-application discussions with the local
planning authority
7.2.2
Preparation of the submission
7.2.3
Submission of a screening and scoping opinion
7.2.4
Development of proposals
7.2.5
Consultation
7.2.6
Refinement of proposals
7.2.7
Determination period
7.2.8
Post screen

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94
94
94
94
95
95
96
96
96

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Contents
8

PERMITTING

99

8.1

England and Wales

100

8.2
8.2.1
8.2.2
8.2.3

Exemptions
T24 exemption for on-farm AD
T25 exemption for off-farm AD
Exemptions for spreading digestate

100
100
100
101

8.3
8.3.1

8.3.2

8.3.3

8.3.4

8.3.5

8.3.6

8.3.7


8.3.8

Standard rules environmental permits

101
Standard rules for on-farm AD installation
(SR2012 No9)
101
Standard rules for on-farm AD waste operation
(SR2012 No10)
102
Standard rules for off-farm AD installations
(SR2012 No11)
102
Standard rules for off-farm AD waste operations
(SR2012 No12)
102
Standard rules for storage of digestate from AD plants
(SR2010 No17)
103
Standard rules for the use of mobile plant for land
spreading (SR2010 No4)
103
Standard rules for combustion of biogas as a
fuel in engines at a sewage treatment works
(SR2009 No4)
103
Health warning
103

8.4
8.4.1
8.4.2

Bespoke environmental permits

Waste facility/operation
Schedule 1 Activity (Listed Activity)

103
103
104

8.5
8.5.1
8.5.2

Permitting in Scotland and Northern Ireland

Scotland
Northern Ireland

104
104
104

9 funding the project

105

9.1
9.1.1
9.1.2
9.1.3

Finance
Bank or debt finance
Equity finance (investment funds)
Reducing the amount of collateral required

106
106
106
106

9.2
9.2.1
9.2.2
9.2.3
9.2.4

Financial incentives
Feed-in Tariff (FIT)
Renewables Obligation Certificates (ROC)
Renewable Heat Incentive (RHI)
Renewable Transport Fuels Obligation (RTFO)

107
107
109
109
110

9.3
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
9.3.6

Insurance
Insurance market overview
Risks to be considered and insurance solutions
Assets
Income
Liabilities
Legal protection

111
111
111
112
112
112
112

The practical guide to AD

10 LEGAL And contractual matters

115

10.1
10.1.1
10.1.2

Legal structures
Corporate structures
Contract structures

116
116
116

10.2
10.2.1
10.2.2
10.2.3

Joint ventures
Control of decision making
Project financing
Deadlock resolution procedures

116
117
117
117

10.3
10.3.1
10.3.2

Bank funding/debt finance

Documentation required for AD project financing
Lenders advisors

117
117
119

10.4

Equity funding

119

10.5
10.5.1
10.5.2
10.5.3
10.5.4
10.5.5
10.5.6
10.5.7
10.5.8
10.5.9

Feedstock supply
Feedstock specification
Delivery
Unloading, weighing and inspection
Transfer of title and risk
Term and price
Shortfall in feedstock
Force majeure
Project lenders
Summary

120
121
121
121
121
121
121
121
121
122

10.6

Construction, engineering, operation and

maintenance contracts

122

10.7
10.7.1
10.7.2
10.7.3
10.7.4

Real estate issues

Site identification
Legal process
Option
Lease

122
122
122
123
123

10.8
10.8.1
10.8.2
10.8.3
10.8.4
10.8.5
10.8.6

Insolvency and default

Termination rights
Turnkey projects
Residual asset value
Step-in rights
Sinking fund
Options

123
124
124
124
124
124
124

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11

TRAINING

Contents
125

13

appendix: HEALTH AND SAFETY

153

11.1
Training overview
126
11.1.1 Why train your staff?
126
11.1.2 Differences between training, qualifications and
competence
126

13.1

An introduction to health and safety

154

13.2

How to use this appendix

154

13.3

Managing health and safety

155

11.2

11.2.1
11.2.2
11.2.3

Technical competence requirements for

permitted facilities
England and Wales
Scotland
Northern Ireland

13.4

Slips, trips and falls

155

126
127
127
127

13.5

Asbestos

156

13.6

Hazardous substances

156

13.7

Falls from a height

157

11.3

Identifying training needs

127

13.8

Musculoskeletal disorders

157

11.4

Maintaining and updating knowledge and skills

129

13.9

Display screen equipment

158

11.5
11.5.1

11.5.2

11.5.3

11.5.4
11.5.5
11.5.6
11.5.7

Who can help?

ADBA (The Anaerobic Digestion and
Biogas Association)
CIWM (The Chartered Institution of
Wastes Management)
WAMITAB (The Waste Management Industry
Training and Advisory Board)
WRAP (Waste & Resources Action Programme)
EU Skills (Energy and Utility Skills)
NSA (National Skills Academy)
AD Portal

129

13.10

Noise

158

13.11

Vibration

159

13.12

Electricity

159

13.13

Work equipment and machinery

160

13.14

Maintenance and building work

160

13.15

Workplace transport

161

13.16

Pressure systems

161

13.17

Fire and explosion

162

13.18

Radiation

162

13.19

Stress

163

13.20

First aid and accident reporting

163

129
129
129
129
129
129
129

12 HEALTH AND SAFETY AWARENESS

131

12.1

12.1.1
12.1.2
12.1.3

Key stages in a project and who needs to

be involved
Responsibilities of the different parties
Safety issues to be addressed at each stage
Hazards awareness

132
132
133
138

12.2
12.2.1

Safe design and operability

Safety management systems and safe
systems of work

138

12.3
12.3.1
12.3.2
12.3.3
12.3.4

12.3.5
12.3.6

Regulations
Implications and application of DSEAR and ATEX
Biological hazards in the workplace
Asbestos
CDM Construction (Design and Management)
Regulations
Management of health and safety at work
Capabilities and training

141
141
144
144

12.4
12.4.1
12.4.2
12.4.3

Managing specific risks

Working at height
Confined Spaces Regulations 1997
Developing a safe system of work

146
146
148
151

AD TERMS AND ACRONYMS

165

138

144
146
146

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Contributors
Review Team
Dr. Robin Szmidt, Managing Director,
Kuttner (UK) Ltd

Dorian Harrison, Technical Director,

Monsal and ADBA Director

After studying at the Universities of London and Stirling, Robin

worked for ADAS and SAC before joining Kuttner (UK) Ltd, a
subsidiary of Kuttner GmbH and a licensee for Kompogas
Dry-AD. Experienced in AD projects worldwide, Robin was involved in
consultations for PAS 100 and PAS 110 and is a member of the UK Register
of Expert Witnesses. Robin belongs to a number of international industry
groups and is Chair of ADBAs Dry AD Working Group.

Monsal has the largest team of advanced digestion technology

specialists in the UK and is a leading supplier of anaerobic
digestion solutions. Monsal technology is becoming widely
recognised as the technology of choice by developers, utilities, county
councils, food producers, waste management companies and farmers in
the UK, delivering comprehensive turnkey solutions, from design and build
through to post-commissioning support and operation.

Terence Brownhill, Director,

Eaton Management and ADBA Director

Amaya Arias-Garcia,
Engineering Manager, Tamar Energy

Chair of ADBAs Training and Safety Working Group, Terence

is a business manager with 10 years experience of operations
management in the mining and engineering sector, and 28 years
operational and business development experience in the waste management
sector. For the past eight years, Terence has been at the forefront of AD
project delivery in the UK.

With over 12 years experience in developing and implementing

engineering solutions in the environmental sector, Amaya
previously worked as Anaerobic Digestion Development Manager
for TEG Environmental and has been involved in the development of a
number of AD plants in the UK. Keen to further the successful development
of the UKs AD industry, Amaya is a regular speaker at AD conferences and
exhibitions and is also Chair of ADBAs Best Practice Working Group.

Claire Henson,
Special Advisor, WRAP

Mark Bedford, Director,

Wardell Armstrong LLP

An environmentalist with a background in both private and

public sector delivery, Claire joined WRAP in 2006 with
responsibility for procurement and State Aid and has since
helped to deliver over three quarters of a million tonnes of new capacity
for green and food waste recycling. Claire now leads WRAPs work on all
infrastructure development, and provides technical and strategic support to
WRAPs stakeholders.

Project Director for Wardell Armstrong, delivering infrastructure,

renewable energy and waste projects, Mark is a Chartered
Surveyor, Chartered Waste Manager, Chartered Environmentalist
and Honorary Fellow of the Society of the Environment. Marks previous
roles include Midland Centre Chairman of CIWM and non-executive director
of the Institute of Wastes Management Business Services Limited, and he is
a former Chair of ADBAs Planning & Permitting Working Group.

Dr. Les Gornall, Process Consultant, PROjEN BioEnergy

A Fellow of the Society of Biology, Les has been building anaerobic digesters since 1978. In the early 1980s, his work on farm waste digestion led
to Irelands first full-scale farm digester and in-vessel composter. After a career building fermenters and commissioning numerous iconic and award
winning plants as an independent manufacturer, Les now heads the technical team at PROjEN BioEnergy, designing, building and commissioning
anaerobic digesters from farm-scale to 120,000 tpa facilities.

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Contributors

Other Contributors
Tom Brassington, ADAS UK Ltd

Dawn Terry, Local Generation

Matt Hindle, ADBA

Linda Coe, Maclay Murray and Spens LLP

Graeme Vincent, Biogen

Paul Davies ACII,

Nviro Insurance & Risk Management Ltd

Paul Stark, Biotec Ltd

Carl Thompson, Osborne Clark

Georgie Messent, Bond Pearce

Stuart Cleak, Osborne Clark

Christopher Towner, Bond Pearce

Campbell Hutcheon, Pinsent Masons

Esther Kiddle, Bond Pearce

Kate Turner, Pinsent Masons

Nick Churchwood, Burges Salmon

Nicola Bowen, Projen PLC

Catherine Goode, Burges Salmon

Leasley Eaton, Seepex UK Ltd

Stephen McCulloch, Chesterfield Biogas

Stephen Wise, Shanks Waste Management Ltd

Tina Benfield, CIWM

Gail Orr, Shanks Waste Management Ltd

Claire Poole, CIWM

Pat Howe, SSE

Alex Marshall, Clarke Energy

Adam Bradley, Taylor Vinters

Wayne Middleton, Digestate Solutions

Mike Orr, The Teg Group

Bora Kulac, E.ON Bioerdgas GmbH

Mike Lee, Uniflare Ltd

Michael Chesshire, Evergreen Gas

Marcus Jones, Uniflare Ltd

David Kinnersley, Fisher German

Ben Sheppard, Walker Morris

Tom Burniston, Geotech

Ray Burberry, Wamitab

Greg Hilton, GG Eco Solutions Limited

Stephen Barnes, Wardell Armstrong LLP

Patrick Pierrepont, Hyder Consulting (UK) Ltd

David Bridgewood, Wardell Armstrong LLP

Duncan Wildgoose, Imtech Water, Waste and Energy

David Tompkins, WRAP

Martin Flach, IVECO

Steven Blues, Zebec Biogas

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The practical guide to AD

Sponsors Page

FM BioEnergy is delighted to be the sponsor of The Practical Guide to AD and congratulates ADBA and its contributors on
producing such an informative and useful guide.
We specialise in AD nutrition, delivering optimum plant output at the least cost of production. Working in both the farm and
industrial biogas sectors, we offer a range of services designed to improve and optimise your gas output and as a result, your
return on investment.
FM BioEnergy provides its services in cooperation with Schaumann BioEnergy who are the market leading AD nutrition company
in Germany. With our joint expertise in the field of anaerobic digestion and efficient feedstock conversion both in Europe and
around the world we are a competent partner for your enterprise.
FM BioEnergy offers the following services:
Consultancy
FM BioConsult provides a specialist start up consultancy which will have your plant up and running at full load within 6
weeks from the start of feeding.
Nutrient Balance
customised technical solutions including liquid and powder trace elements to correct deficiencies and deliver enhanced
fermentation and substrate utilisation.
GasPlan Diet Formulation
a unique diet formulation service, delivering the optimum least cost diet to meet the output requirement of your plant.
This service also combines a what if formulation ability for you to evaluate new raw materials or throughput options in
terms of cost benefit decisions.
Feedstock Supply
the supply of cost effective alternative substrates from the human food and drinks industries throughout the UK.
Laboratory Services
full process control including the complete analysis of feedstock quality and digester nutrients. Accurate results from an
accredited biogas laboratory according to EN ISO/IEC 17025.
Gas Leakage Detection
checking the methane volatilization on your AD plant helping to ensure safety and higher profits. Methane sensitive cameras
and lasers and IR-devices detect every leakage on your plant.

Training
training across all aspects of plant nutrition and biology, from centres in the UK and Germany.

FM BioEnergy, Unit 15A, Gelders Hall Road, Shepshed, Loughborough, LE12 9NH.
Email: [email protected] phone: 0871 7043317 www.fmbioenergy.co.uk
10

The practical guide to AD

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