Mackie’s of Scotland… Renewable ice-cream?

Mackie’s is a 1600 acre Westertown farm located at Aberdeenshire, using green power to run their industry- including the byre, ice-cream dairy and chocolate factory.

This Scottish food industry produces 70% of its energy from a mix of renewable generation, with wind being the main source. They have four wind turbines with a total capacity of 3MW- 3 Vestas 850 kW and 1 Enercon 500kW Wind Turbine. A 10-acre site of solar panels with a total installed capacity of 1.8 MW-6,912 individual panels each with 260W capacity, in addition to a smaller array of solar panels on the byre roof, contributing to the electricity needs. Moreover, heating power for the office and houses is generated from a 400kW biomass plant.

A good mix of these power types is provided which helps producing peaks at different times and for achieving their goal to be a self-sufficient industry.

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At Mackie’s, they are committed to good environmental stewardship and their company vision is to be a Scottish global brand from the greenest company in Britain created by people.

Why Mackie’s as a case study?

The current system still lacks dispachability to meet the peak energy demands and approximately 1.3 GWhr of electricity is purchased from the grid!

Several factors identified in the literature review will be adopted for the biogas plant as they are prerequisites for its production. These are the processes of hydrolysis, acidogenesis, acetogenesis and methanogenesis. Many factors are dependent upon each other as the selection of feedstock and type of fermentation are crucial for producing an effective system. The wet digestion fermentation will be adopted as it allows a wide variety of feedstocks regardless of their solid content. The main type of feedstock that will be used in the case study will be manure due to the location of the site being next to a dairy farm, but the use of wet fermentation allows the methodology to be applicable for sites where there is limited access to manure. The Mackie’s case study will produce a waste product from the ice cream manufacturing process that can be used in the anaerobic digestion process. The biogas plant will operate in the Thermophilic temperature range between 45-60 oC as it reduces the retention time and the reactor volume. The requirements of the site mean that a continuous process must be used as it allows for the stable production of biogas and is adaptable to various digesters, which increases the versatility of the methodology.

Environmental Impact Assessment (EIA)

EIA was carried out to determine the impacts of our proposed system and its significance to the surrounding environment. The assessment was carried out with the use of matrices to determine the impact significance from every component. With the help of the matrix analysis, the cumulative impacts were assessed.

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Green :1-3 Low Significance Orange: 4-6 Medium Significance Red: 7-10 High Significance

Based on the results of EIA analysis, the overall impact significance of our proposed system is within the acceptable range.

Wind

Land Use and Visual impact

The four wind turbines of Mackie’s are well spaced (approx. 5 to 10 wind turbine blade dia. apart) and the turbines occupy only a small portion of the land. (NHMRC, 2010). The wind farm doesn’t interfere with the usage of any areas such as recreational or biodiversity.

Noise

Noise from the turbines depends on the design module and wind speed but since people don’t live in the close proximity to the wind turbines, the noise effect isn’t significant.

Solar

Land Use and Visual impact

Mackie’s have a solar farm of 10 acres but since the land is private and at a lower-quality location, the land impacts are minimal. It doesn’t affect the recreational areas or wilderness (Greenmatch, 2019). Moreover, they have effectively added solar panels on the byre roof.

Biogas

Greenhouse Effect

The GHG emissions from the electricity production of a biogas plant can be mitigated by continual evaluation of monitoring data such as reducing the direct methane emission and leakage, exploiting the heat from cogeneration, amount and nature of input material, nitrous oxide emission control and digestate management. Considering cattle manure as the feedstock for the biogas plant, a well operating digestate processing and handling could reduce the methane emissions. Closed storage for manure and co-digestion feeding can reduce ammonia emissions. (Valerio, Francesco, Marco, Laura, Nour & Angelo,2018)

Air Quality and Odour

The parameters such as the feedstock and digestate storage units are essential requirements for the best design and management of a biogas plant which helps in mitigating the odour impact. (Valerio, Francesco, Marco, Laura, Nour & Angelo,2018)

Lithium-Ion Battery

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Software Analysis

To allow analysis to be performed on Mackie’s Hybrid Energy Generation System with our proposed system of adding a biogas generator as dispatchable energy generation and energy storage as energy buffering, we modelled and optimised the system based on the information provided by Mackie’s Scotland. Homer Pro was used to carry out analysis for our case study on Mackie’s Scotland. Constraints were set to achieve 100% renewable fraction and full energy autonomy from the grid. In order to achieve full renewable energy autonomy, the power supply and demand of the site must be balanced throughout the year. Any unmet electrical load would cause disruptions to the operations of the industrial site, which can lead to severe capital losses. Full details can be accessed from here.

Financial Analysis

To establish feasibility of the proposed optimised hybrid energy system comprising of wind, solar, and biogas along with a Lithium-ion battery storage system, financial modelling of the system was undertaken. Assumptions are made to estimate the capital cost of all components. Furthermore, payback period and Internal Return Rate (IRR) were calculated to determine the feasibility of our proposed system. Full details of the analysis can be accessed from here.

References

Greenmatch.co.uk. (2019). Environmental Impact Of Solar Energy | GreenMatch. [online] Available at: https://www.greenmatch.co.uk/blog/2015/01/impact-of-solar-energy-on-the-environment [Accessed 13 April 2019].

National Health and Medical Research Council (NHMRC). 2010. Wind turbines and health: A rapid review of the evidence. Canberra, Australia: National Health and Medical Research Council.[Accessed 29 Apr. 2019].

Valerio Paolini, Francesco Petracchini, Marco Segreto, Laura Tomassetti, Nour Naja & Angelo Cecinato (2018) Environmental impact of biogas: A short review of current knowledge, Journal of Environmental Science and Health.Available at: https://www.tandfonline.com/doi/pdf/10.1080/10934529.2018.1459076?needAccess=true [Accessed 25 Apr. 2019].