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EISENMANN
ISENMAN
Clean Air & Energy Technology
Sustainability in an Urban Environment
through Anaerobic Digestion
An Overview of how one Urban Farm is Fighting the
Food Desert Epidemic by Utilizing Anaerobic Digestion
to Create a Net-Zero Energy System
EISENMANN Corporation
[email protected]
www.eisenmann.com/usa815.455.4100
Table of Contents
Defining a Food Desert
Major Implications
Identifying Current Initiatives
Local Efforts
Building The Plant
Using Anaerobic Digestion
Renewable Energy at The Plant
Choosing Eisenmann Technology
The Anaerobic Digester at The Plant
The Eisenmann Advantage
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3
4
6
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List of Exhibits
1 - USDA Food Desert Definition
2 - USDA Map of Food Desert in the US
3 - City of Chicago: Urban Agriculture Zoning Code Amendment
4 - The Plant Operations Diagram
5 - The Plant Building Rendering
6 - Anaerobic Digestion Phases
7 - Renewable Energy Process Flow Diagram
8 - Rendering of The Plant’s Anaerobic Digester
9 - Eisenmann Biogas Key Data at The Plant
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4
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6
7
8
8
Appendices
1 - The Plant’s Major Milestones
2 - Benefits of The Plant and the Anaerobic Digestion System
3 - Organic Input Substrates and Biogas Yield
4 - About Eisenmann Corporation
www.eisenmann.com/usa
Sustainability in an Urban Environment
through Anaerobic Digestion
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EISENMANN
Defining a Food Desert
Many urban areas face a significant problem with older, industrial distressed neighborhoods. These neighborhoods, often historically a booming industrial area, have
now become sore spots, both visually and economically on a city. The residents in
these areas more often that not, suffer from things such as a lack of available jobs
and a lack of available fresh produce and food options.
These areas, where there is a lack of fresh, healthy, affordable food, have become
known as food deserts. The US Department of Agriculture defines a food desert
as urban neighborhoods and rural towns without ready access to fresh, healthy,
and affordable food (Exhibit 1)1. The estimated 23.5 million Americans that live in
these areas experience physical and economic barriers to accessing healthy foods,
including the availability of nutritious foods, the affordability of foods, or just a lack
of access to food retailers (Exhibit 2)
Exhibit 1
USDA Food Desert Definition
“low-income census tract where a substantial number or
share of residents have low access to a supermarket or
large grocery store”
“Low-income community” Qualifications:
- poverty rate of 20% or higher
OR
- median family income at or be
low 80% of the area median family income
“Low-access community Qualifications:
- at least 500 people and/or at least 33% of the tract population reside more than one mile from a supermarket or
large grocery store (in rural areas the distance increases to
ten miles)
Major Implications
The major impact of these food deserts is the affect on the local populations. In a
USDA report to Congress, it was noted that increases in obesity and diet-related
diseases are major health problems and that these problems may be worse in some
US communities where access to affordable and nutritious foods is difficult.2 This
lack of access contributes directly to poor diets which can lead to obesity. However, even knowledge of good nutrition and the best of intentions cannot provide
the access needed to affordable, healthy foods in these communities.
1 US Department of Agriculture, www.usda.gov
2 US Department of Agriculture, Access to Affordable and Nutritious Food: Measuring and Understanding Food Deserts and Their Consequences, http://www.ers.usda.gov/publications/ap/ap036/ap036.pdf
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Sustainability in an Urban Environment
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Exbibit 2 - US Department of Agriculture Map of Food Deserts in the USA
Identifying Current Initiatives
There are several initiatives in place to address the food desert epidemic. On the
national level, programs such as Let’s Move, a federal government program working in conjunction with the USDA, is dedicated to solving the challenge of childhood
obesity, providing parents with helpful information that support healthy choices,
and ensuring that every family has access to healthy affordable food.1 As part of
this initiative, the Departments of Agriculture, Treasury, and Health and Human
Services are working together to expand the availability of nutritious foods by connecting producers and consumers.
Currently, 19 grant opportunities are available through these three departments
that support the development of substainable programs and strategies seeking to
eliminate food deserts. These programs aim to assist local and state governments,
non-profit organizations, institutions, businesses, and residents in affected communities. The goal is to increase access to healthy food, which will improve public
health, create jobs, help revitalize distressed communities, and open new markets
for farmers to sell their products. Programs such as the USDA’s Community Food
Projects Competitive Grant Program and Farmer’s Market Promotion Program have
already led to advances in cities such New York City and Detroit.
1 Let’s Move, www.letsmove.gov
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Sustainability in an Urban Environment
through Anaerobic Digestion
EISENMANN
Local Efforts
Cities and communities are also taking action in their own neighborhoods. Local
grant programs and city ordinances are being developed and passed which have
resulted in many local programs such as farmer’s markets, community gardens,
local food production and promotion, alternative agriculture such as hydroponics
and aquaponics, youth agriculture, and culinary training programs.
One such ordinance, the Urban Agriculture Zoning Code Amendment in the City of
Chicago, encourages more urban farming (Exhibit 3). This new zoning code will
promote the expansion of community gardening and urban agriculture within the
city boundaries by legalizing urban farming of vegetables, fruits, and fish and will
permit owners to sell what they raise. With a goal of eliminating food deserts in
disadvantaged areas of the city, there is hope this ordinance will create green jobs
and fresh produce across the city. In an article on its website, Sustainable Chicago
says that there are financial and social benefits to urban agriculture including a
renewable food source, better health and nutrition options, increased incomes,
employment, and a community social life.1
Exhibit 3
Urban Agriculture Zoning Code Amendment
- City of Chicago
New zoning code provisions:
- Expand the size limit on community gardens to 25,000 square
feet
- Relax fencing and parking requirements on larger commercial
urban farms in order to hold down overhead costs for entrepreneurs and community organizations that launch and maintain these enterprises
- Allow for hydroponic and aquaponic systems and keeping
honey bees under set conditions
- Create green jobs and provide fresh produce in communities
Local grants and the new zoning codes have resulted in the city’s first urban vertical
farm, which is currently being developed in south Chicago. The project, known
as The Plant, operates as both a non-profit and for-profit organization offering a
vertical farm in a food desert and a food-business incubator in a distressed neighborhood. The organization will also focus on research and education but the most
ambitious part of the entire thing is the renewable energy system that will make
the building net-zero energy and completely self-sustaining.
1 Sustainable Chicago, New Ordinance Encourages More Urban Farming, http://www.sustainable-chicago.com/2011/09/28/new-ordincase-encourages-more-urban-farming/
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Sustainability in an Urban Environment
through Anaerobic Digestion
EISENMANN
Building The Plant
What began as a 93,500 s.f. meatpacking facility in the Chicago stockyards, has now
become The Plant, a net-zero energy vertical farm and food business operation.
The Plant is dedicated to promoting sustainable food production, entreprenuership, and building reuse through research, education, and development (Exhibit 4).
Exbibit 4 - The Plant Operations Diagram
The following outlines the features and benefits of The Plant’s operation:1
Verticle Farm
The Plant defines vertical farming as farming in multiple stories of a building and from
floor to ceiling in a room. This provides planting of more layers of crops per square acre
than a flat farming surface and provides a sustainable food source in an urban food desert. Future plans include the incorporation of living walls, planting a rooftop garden,
and raising bees and potentially chickens.
Aquaponics
The basement of the old meatpacking plant is now home to an aquaponic ecosystem.
This is the combination of a fish farm and plants growing in water without soil into an
almost fully enclosed system that creates a symbiotic relationship. The fish, in this case
Tilapia, produce ammonia-based waste that is filtered and broken down into nitrates.
Those nitrates are fed to the vegetables in hydroponic beds which absord the nitrates
and clean the water to be returned to the fish. The fish and vegetables will be sold to
local food markets and restaurants.
1 The Plant Chicago, www.plantchicago.com
1 Let’s Move, www.letsmove.gov
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Food-Business
Incubator
Another intregral part of The Plant are the food businesses which currently include a
beer brewery, kombucha tea brewery, bakery, mushroom farm, and a shared kitchen.
In keeping with the theme, these businesses are all part of the interconnected, selfsustaining system where waste from one is used as food for another. For example, the
grains from the brewery feed the tilapia and solid waste from the talipia will be fed to
the mushrooms. This allows the businesses of The Plant to grow and prosper together,
at low rent and low energy costs, while also creating 125 new, green jobs in a struggling
community.
Education and
Research
The Plant plans to host seminars for sustainability professionals, college students,
school children, and the public on a wide range of topics including things such as energy and efficiency in buildings, obesity and healthy eating, and growing techniques.
The goal is to touch as many people as possible to foster a new, sustainable direction
in agriculture.
Building Reuse
By repurposing an abandoned food processing plant, the organization is combining
manufacturing and growing plants indoors, both of which take a lot of energy and can
be done in a sustainable way. The point is to act as an example that all kinds of closed
industrial facilities and buildings can be repurposed to house many different kinds of
manufacturing and growing systems.
Renewable Energy The Plant aims to be a completely off the grid, closed loop system, that is net-zero enSystem
ergy and self-sustaining. The building’s food businesses will provide the organic waste
that will be turned into energy through an anaerobic digester and a repurposed jet engine acting as a combined heat and power unit. This, in turn, will provide the electricity
and process heat needed by the businesses in the building. By using the organic waste
to feed the digester, they will also successfully divert 5,000 tons of waste from landfills
each year.
Exbibit 5 - The Plant Building Rendering
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Sustainability in an Urban Environment
through Anaerobic Digestion
EISENMANN
Using Anaerobic Digestion
Anaerobic Digestion is the degradation and stabilization of organic material generating a mixture of methane and carbon dioxide (called Biogas) by bacteria in an oxygen free environment. The process occurs in four stages (Exhibit 6) and the result
is several bi-products including biogas and both solid and liquid soil amendments.
Exhibit 6
Anaerobic Digestion Phases:
1. Hydrolosis
- The proteins, carbohydrates, and fats are broken down
by bacteria into amino acids
2. Acidogenesis
- The amino acids are transformed by acidogenic bacteria
into short chain volital acids, ketones, alcohols, hydrogen,
and carbon dioxide
3. Acetogenesis
- The remaining acids are transformed by acetogenic
bacteria into hydrogen, carbon dioxide, and acetic acid
4. Methanogenesis
- The hydrogen and acetic acids are converted by
methanogenic bacteria into methane gas and
carbon dioxide
Renewable Energy at The Plant
As part of the renewable energy system, The Plant will be using an anaerobic digester combined with a combined heat and power (CHP) unit. This system will convert
organic waste into biogas which will be released to the CHP to supply the building
with heat and electricity.
Funded in part by grant money from the Illinois Department of Commerce and Economic Opportunity, the anaerobic digester will be installed behind the building.
The system will consume 13 tons of food waste a day (roughly 5,000 tons annually). The waste will include all of the waste produced at The Plant as well as by
neighboring food manufacturers.
The digester will produce 2.2 million Btu per hour of biogas, which will be captured
and burned in the CHP to produce 200kwH of electricity. This will also produce
enough process heat needed by the brewery operations and to regulate the building’s temperature (Exhibit 7).
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Sustainability in an Urban Environment
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Exbibit 7 - Renewable Energy System Process Flow Diagram
Biowaste
Conditioning
Combined Heat and
Power Generator
Electrical
Energy
Seperator
Thermal
Energy
Compost
Main Digester
Pump
Compost
Fertilizer
Final Storage Tank
Liquid Substrates
Choosing Eisenmann Technology
Eisenmann’s proprietary BIOGAS Green Waste technology uses anaerobic digestion
to convert high solid waste organics to biogas. The BIOGAS-GW continuously
mixed horizontal high solids anaerobic digestion system can handle a broad range
of organic streams. This flexibility, a main reason The Plant chose Eisenmann
technology, allows operators to receive a variety of wastes from a multitude of
sources.
The modular pre-engineered design of the BIOGAS-GW takes advantage of the latest in material handling and feedstock pre-processing tecnologies. A typical system includes multiple input channels to accept a range of feedstock and the
ability to seperate unwanted contamination. The closed system design mitigates
concern over odor. Eisenmann’s proprietary custom blended micro-nutrient additives assure that the system is always operating at peak health and extracting the
most potential from the renewable energy feedstock.
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Sustainability in an Urban Environment
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EISENMANN
The Anaerobic Digester at The Plant
Eisenmann technology is a critical component to the success of the renewable energy sustainability at The Plant. The project, which will be completed in two phases,
provides the most flexibility in feedstock in the smallest possible footprint (Exhibit
8). These were both key benefits for The Plant.
Exbibit 8 - Rendering of The Plant’s Anaerobic Digester
There are also other distinctive features that were beneficial to The Plant. The digester technology is a robust and durable design that offers a fully automated,
continuous feed system. All substrates can be fed into the digerster without the
need to slurry. The system handles a high dry matter content in which a variety of
organic waste sources can be used including input substrates from:
- Food processing facilities
- Retaurants
- Waste management facilities
- Agriculture, yard waste and grass clippings
The system custom designed for The Plant provided the desired input capacity resulting in the maximum output in the available footprint for an urban environment
(Exhibit 9).
Exbibit 9 - Eisenmann Biogas Key Data at The Plant
Overall Footprint
Input
Offtake
80 ft. x 170 ft.
5,000 tons/year of organic waste
2.2 million Btu/hr of Biogas
200 kwH of electricity
1 ton/day of press-cake for composting
8 tons/day of liquid soil amendment
(to replace fossil fuel based fertilizer)
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Sustainability in an Urban Environment
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EISENMANN
The Eisenmann Advantage
Eisenmann understands that success in the organic diversion/organic waste-to-energy market requires experience, resources, and end-to-end process knowledge of
how to optimize front end flexibility, renewable energy generation and the value of
co-products to achieve the best and most sustainable return on investments.
Eisenmann’s technology is used in more than 90 biogas plants to date, ranging in
processing size from 12 tons per day to over 160 tons per day as well as over 800
water treatment plants throughout the world.
Working together with industry veterans and over 3,600 employees, Eisenmann offers the strength and experience of a global solutions provider combined with local experience in executing over 1000 projects in North America over the past 35
years.
Phone:
815-455-4100
Email: [email protected]
Web: www.eisenmann.us.com
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Sustainability in an Urban Environment
through Anaerobic Digestion
EISENMANN
Appendix 1 - The Plant Milestones
July 1, 2010
September 2010
October 2010
January 2011
February 2011
December 2011
March 2012
April/May 2012
June 2012
January 2013
Acquisition of building
Begin Renovation
First permanent tenant move in (Thrive Artesian Kombucha Teas)
First kitchen/bakery operational
Plant Chicago NFP was founded
Purchase decision for Biogas Plant
Installation of combined heat and power unit
Finalizing of permitting for Biogas plant construction
Begin construction of Biogas Plant
Biogas plant startup
Appendix 2 - Benefits of The Plant and the Anaerobic Digestion System
- Sustainable urban agriculture in a food desert
- Creation of 125 jobs in a distressed neighborhood
- Repurposing of a 93.500 sq. ft. abandoned meat packing plant in Chicago’s “Back of the Yard”
Neighborhood
- Incubation of sustainable foods businesses offering low rent, low energy costs
- Implementation of an aquaponics growing system
- Creation of licensed shared kitchen rentals
- Net-zero energy system, self-sustaining
- Diversion of 5,000 tons of organic waste from landfills each year
(Organic waste makes up 24% of materials sent to landfills in the US)
- Reduction of Green House Gas emmissions by utilizing
waste streams in onsite Biogas plant
- Economic benefit by creating renewable energy for a microgrid
- Use of digestate rather than fossil fuel based fertilizer
- Reducing carbon footprint by eliminating waste collection truck traffic
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EISENMANN
Appendix 3 - Organic Input Substrates and Biogas Yield
Biogas Yields
200
Biogas Yield [m3/t fresh mass]
202
172 163
150
128
100
111 108
100
88 80
70
67
50
60
45
40
28
25
Be
et
Le
av
es
Pr
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se
d
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lp
Pi
g
Ma
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re
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ttl
eM
an
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e
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ai
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St
ill
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e
id
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g
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ow
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or
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um
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(w
ho
le
Ry
e
Si
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ge
M
aiz
e
Si
la
ge
0
Methane Content [%]
Maize Silage
Rye Silage (whole plant)
Grass Silage
Sudan Grass
Feeding Beet
Sweet Sorghum
Biowaste
Common Beet
52
54
52
55
51
54
61
53
Poultry Manure
Beet Leaves
Pressed Pulp
Pig Manure
Cattle Manure
Grain Stillage
Liquid Pig Manure
Liquid Cattle Manure
60
54
72
60
60
61
65
60
Source: AEBIOM Roadmap to Biogas 2010
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Sustainability in an Urban Environment
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Appendix 4 - About Eisenmann Corporation
Eisenmann is a leading global industrial solutions provider with US headquarters based outside of Chicago, IL. Working closely with a variety of industries, Eisenmann has leveraged their global resources
of over 3,600 employees and more than 60 years of experience to address the demand for solutions
that lower operating costs and optimize plant operations.
Today, the company remains a key player in the development of environmental technologies. They
are a leading supplier of regenerative thermal oxidizers (RTOs) to the renewable fuels industry and
have expanded their product portfolio to include a variety of renewable energy products and waste to
energy solutions.
Facts & Figures
- Established in Stuttgart, Germany in 1951
- 12 locations worldwide
- US location Crystal Lake, IL since late 70‘s
- Global workforce of approx. 3,600 employees
- More than 90 Biogas facilities built to date
Eisenmann Offers:
- Reference installations worldwide
- Custom and modular solutions
- Global services
- Detailed system and process solutions
- Top quality and reliability
Eisenmann Specializes in:
- Plant engineering
- Highly flexible systems integration
- Market and technology leader for individual
components and entire systems
- Service provider with a broad service offering
Eisenmann is a Leading International Supplier of:
- Paint finishing systems
- Environmental technology
- Material handling & conveyor systems
- Process and high-temperature technology
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