Clearfleau, a food and beverage firm, is set to launch an anaerobic digestion (AD) plant, which will use bio-methane generated exclusively from cheese production residues.

The £10m plant was designed and built in Cumbria, UK for Lake District Biogas, which will operate the plant for 20 years, using feedstock such as process rinses from dairy producer First Milk’s nearby Aspatria cheese creamery.
The plant will treat 1,650 m3 of cheese-processing waste and generate around 5 MW/d of thermal energy. Clearfleau says the plant is expected to be operating at full capacity later in the spring.

The plant will produce bio-methane at a rate of up to 1,000 m3/h. Over 80% of which will be upgraded to be injected into the gas grid. Most of this will be used to supply 25% of the creamery’s energy requirement, and the rest to be used by local businesses and households in Cumbria. The plant is set to save approximately £3m/y, through government incentives and sale of the excess gas.

Clearfleau’s process takes the feedstock from the creamery, comprising low-strength wash waters such as process rinses, and whey permeate. The liquid is then pumped into the AD plant from the creamery where microorganisms convert the fats and sugars in the feedstock into biogas.

The biogas is stored in a gas dome, where 80% of the gas is fed into a membrane-based upgrade unit that removes CO2 to produce bio-methane.