Project Outline

The Huddersfield Energy & Recycling Facility project involves the construction and commissioning of a new mesophilic anaerobic digestion facility that will produce renewable electricity from sewage sludge while also producing a high-quality lime stablised sludge suitable for sustainable reuse as an agricultural fertiliser.

The project entails demolition of the old sludge incineration and site clearance prior to construction and commissioning of a new facility which includes:

  • New import acceptance facility for both liquid sludge and sludge cake.
  • New sludge thickening plant (drum thickeners) to thicken combined import and SAS to circa 6% dry solids.
  • New holding tanks (2 no.) for mixing and holding re-watered sludge cake and thickened sludge prior to pumped feed to digesters.
  • 2 no. anaerobic digesters each with 7,306m3
  • Biogas storage and handling system comprising biogas treatment (carbon scrubber for siloxane removal), gas holder and flare stack
  • 2 no. 1.2MW CHPs to generate electricity so as to reduce the site reliance on imported power with the waste heat from the CHPs used to heat the digesters.
  • High voltage infrastructure to allow energy generated from the CHP to be fed to the external grid.
  • 1 no. dual fuel boiler (biogas or natural gas) to supplement CHP heat output when required.
  • 47m high exhaust stack for dispersion of exhaust gases from the boiler and CHP.
  • Heat exchangers to transfer heat from CHP to sludge so the digesters are operated in the range 36-39°C.
  • New holding tanks (2 no.) for storage of digested sludge prior to dewatering.
  • Lime dosing facility to allow powdered quick lime to be dosed into the digested sludge so that conventional product status is achieved.
  • 2 no. dewatering centrifuges to produce sludge cake at circa 25% dry solids.
  • Cake barn providing storage for 844m3of sludge cake.
  • Liquor treatment plant to reduce liquor ammonia levels by 85% prior to return to Lower Brighouse STW.
  • Odour control
  • Welfare and laboratory facilities.

Key Challenges

The site is located in an air quality monitoring zone. Dispersion modelling has been used in the design of the exhaust stack for the CHPs and boiler as well in the sizing and location of odour control units to ensure that the completed plant meets stringent quality standards and nuisance odours from the site are avoided.

Project Delivery & Innovations

  • The project has been designed to mitigate against the inherent flood risk at the site with key assets raised above maximum flood water levels to achieve the required resilience.
  • 3D modelling has been used across the project to coordinate design, manufacturing and installation activities, avert clashes and verify installation confirms to design.

Key Facts 

  • Electricity generated by the new facility will be equivalent to that required to power 5,280 homes.
  • The plant will treat 24,000 tonnes (dry solids) of sludge each year.
  • At peak output each CHP will generate up to 1,195kW of electrical power with a thermal output of 1,203kW.

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