How a duck farm in Indiana turned waste into energy with 2G CHP!

Three 2G CHP modules generate electricity and heat from duck waste and other substrates
We are excited to announce that our client, Cluvers Duck Farms Inc, has implemented a cutting-edge CHP system that transforms organic waste into green energy. This system, powered by three 2G agenitor 212 engines, generates 1,200 ekW of electricity per hour and 1,422 kwh/th of thermal heat. They sell the electricity to the local utility company and use the heat to warm their water and facilities. This way, they lower their environmental impact and save on energy costs. Their CHP system also features a 2G Gas Treatment System that purifies the biogas before combustion, ensuring optimal performance and low emissions. We are honored to partner with Cluvers Duck Farms Inc and provide them with this innovative and sustainable solution for their duck farm.

Facts & figures

Application:
Biogas and biomethane plants
Country:
United States
CHP:
3 x agenitor 212
Output el/th (kW):
3 x 400 kWel / 3 x 480 kWth
Operator:
Culver Duck Farms, Inc.

One of the largest duck farms and processing facilities in North America owns a large CHP system located outside of Middlebury in Indiana. The customer processes more than 6.5 million ducks every year, all of which are raised in satellite farms in the surrounding area. In 2011, the company started an anaerobic digester to manage the 18,000 pounds per day of duck droppings and offal generated in its processing plant.

 

The 2G CHP project consists of three fully sound-attenuated containerized CHP modules, each containing a 2G agenitor 212 engine as a prime mover. Each unit has an electrical capacity of 400 ekW/h, providing a total of 1,200 ekW per hour or 9,960 MW/h per year, sold to the local utility company under a 15-year power purchase agreement (PPA). The thermal heat produced is 1,422 kwh/th. This valuable thermal energy is used to heat processing water at the farm's facility, the processing plant, and the digester facility itself. Previously, the farm had to find ways to dispose of all organic waste. The 942,000-gallon capacity digester is designed for and will use a large amount of duck offal combined with corn silage and other substrates to produce high-quality biogas for all three CHP modules. The biogas is first treated and cleaned using a 2G Gas Treatment System consisting of biogas dehumidification for moisture removal before it enters the combustion process for the engine. An additional 2G H2S filtration system was added. The entire power generation process is monitored 24/7.