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MotasemJournal Saidan, of Chemical Hussam J. Technology Khasawneh, and Mohammad Metallurgy, Tayyem, 52, 3, 2017, Mohammed 595-601 Hawari

GETTING FROM POULTRY IN JORDAN: CLEANER PRODUCTION APPROACH

Motasem Saidan1,2, Hussam J. Khasawneh2,3, Mohammad Tayyem4, Mohammed Hawari4

1 The University of Jordan, School of Engineering Received 24 January 2017 Chemical Engineering Department Accepted 06 March 2017 Amman 11942, Jordan E-­mail: [email protected], [email protected] 2 Water, Energy and Environment Center The University of Jordan, Amman, 11942, Jordan 3 The University of Jordan, School of Engineering Mechatronics Engineering Department Amman 11942, Jordan 4 The University of Jordan, School of Engineering Program of Environmental Engineering and (MAPEC) Amman 11942, Jordan

ABSTRACT

Reducing environmental impacts and getting economic benefits, based on the waste utilization, and on the re- duction of both energy consumption and organic load, was the driver of the implementation of cleaner production assessment in a poultry industry and its related processes. The main objective of this study is to examine the feasibil- ity of using poultry as a source of energy to cover the heating demand of Poultry Company’s slaughterhouse. Poultry litter enters the cooking stage to produce the fat-oil for the fuel burning stage. The results showed that the critical price of poultry litter is 46.7 JOD per ton, below which it becomes feasible to utilize this waste as a source of energy. However, the daily monetary saving was found to be strongly affected by the prices of both poultry litter and diesel. Another revenue can be generated from the fertilizer value of the poultry waste-to-energy ash. However, this depends on several technical and market factors that need further clarification. Keywords: poultry litter, slaughterhouse, steam boiler, energy, eco-efficiency, cleaner production.

INTRODUCTION Facilities should find CP assessment instrumental to systematically identifying opportunities to increase The cleaner production (CP) is an in-depth review of energy efficiency and decrease waste generation. Conse- existing operations to increase efficiency of the operation quently, this leads to a positive change in the sustainable through prevention and production and consumption [3 - 6]. It is a well-used [1, 2]. The CP is an essential and valuable tool used to: and proven approach to identifying cost-saving energy (1) define the specific characteristics of a whole facility conservation and technologies that or operation that consumes energy and generates waste, enhance the facility’s performance. (2) identify a range of energy conservation and pollution The agro-food industry provides interesting oppor- prevention options, (3) evaluate the options based on a tunities for the application of this concept, in particular, set of criteria, and (4) select the most promising options due to the energy and water consumption levels and for implementation. generated [7, 8].

595 Journal of Chemical Technology and Metallurgy, 52, 3, 2017

Jordanian statistics in 2013 indicates the availability tion of poultry meat has experienced a slight increase in of around 2125 chicken farms [9]. Excess biomass is year 2014 to reach 30,629 ton in comparison to 30,230 readily available on a poultry operation; this poultry lit- ton in year 2013. Nevertheless, the factory’s annual ter is a viable and renewable energy source with heating report for the year 2013 has shown a number of difficul- value average around 9550 kJ/kg [10, 11], at the same ties facing the company, which hamper the company’s time 96 % of energy supply in Jordan is imported [12]. growth. Difficulties include rising competition among Solid is currently a crucial slaughter shops, fluctuating prices of feeds globally, subject in Jordan. The solid waste generation is ex- swamping the local market with imported frozen chicken pected to increase on account of development activities, leading to a higher competition between suppliers, in- , and changing patterns of Jordanian creasing fuel prices globally, and the emergence of new consumption behavior by approximately 3 % per year companies in this industry. All of these difficulties have [13 - 16]. In addition, changes in public awareness will led to an increase in production and drop in prices. Thus, affect it [17]. this factory works hard to reduce the cost of production, However, poultry-waste-to-energy has the capacity which eventually could increase its profit. to increase and to negatively impact environ- Several detailed visits were carried out to collect mental justice and health if environmentally sound man- necessary data and establish the material, water and agement and best practices are not considered [18, 19]. energy flow analyses. The assessment was focused on Poultry litter is a mixture of heads, feet, intestines, the slaughterhouse to examine the status of current boiler blood, and feathers. According to literature, the uses systems for the future utilization of poultry litter as a of poultry litter as a land fertilizer are constrained due source of energy. to risks of (from and runoff), All data regarding the daily poultry production, per- and spread of diseases. On the other hand, pyrolysis of centage of poultry litter, average daily production of fat- poultry litter by applying thermo-chemical techniques oil, average price per ton of poultry litter, and daily diesel produces usable energy and destroys microorganisms. demand were collected and used for calculations. The The aim of this study is to provide an initial cost- average diesel price for the year 2014 was 0.685 JOD/L benefit analysis for the efficiency of recovering heat from (1 USD equals 0.71 JOD). This number was obtained poultry litter produced at poultry company’s facilities from the Ministry of Energy and Mineral Resources and as an alternative source to meet the heating demands therefore it was used as the reference price for diesel. of the company’s slaughterhouse. Moreover, it is also examined the feasibility of using the simple pyrolysis POULTRY PROCESS DESCRIPTION technique to produce fat-oil from poultry litter (heads, feet, intestines, blood, and feathers). As shown in Fig. 1, chickens are normally transported from several farms and delivered in loose boxes (crates) MATERIALS AND METODS via lorries. During the transportation, the crates, which are made from and have a rectangular shape, are The assessment presented in this paper has been normally contaminated with manure wastes. Conse- carried out following the Guide to Industrial Assess- quently, the manure contamination increases the amount ment for Pollution Prevention and Energy Efficiency in of organic effluent produced during the automated crate order to facilitate it [20]. In this paper, a poultry factory washing equipment after delivery of the chickens. located in Al-Karak Governorate in Jordan, was chosen Having arrived at the slaughterhouse (killing area), as a case study. The company is engaged in the operation the chickens are hung upside down by their feet on a of poultry farms, slaughterhouses, breeder and broiler metallic conveyor which moves them towards the stun- farms, hatcheries, and feed mills. The company manu- ning machine (30-40 volt) and the stunned chickens are factures packs, trades, markets, and distributes poultry moved to the killing line. After being killed, the chicken products, namely eggs and chicken feed. Products of this is bled for up to two minutes while moving on the con- company are distributed throughout the whole country. veyor. The blood is collected in tank, and then it moves According to its annual report, the factory’s produc- through a specific channel. 596 Motasem Saidan, Hussam J. Khasawneh, Mohammad Tayyem, Mohammed Hawari

Fig. 1. Poultry factory’s process flow diagram.

Fig. 2. Poultry factory’s process flow diagram.

After bleeding is complete, the chickens are trans- within the machines for flushing-out feathers. ferred via conveyors to the de-feathering stage, in The removed feathers are taken to a collection point which they are immersed in a scald tank (56 - 58oC) to via a fast-running water channel located below the ma- facilitate the mechanical de-feathering process. So, the chine. The collected feathers are then transferred to a de-feathering stage comprises counter-rotating stainless lorry using a conveyor belt. Other feathers, which escape steel discs with rubber fingers mounted on them, as well through water, can be collected in the grit chamber in as, continuous water sprays are usually incorporated the preliminary wastewater treatment stage.

597 Journal of Chemical Technology and Metallurgy, 52, 3, 2017

After that, the chickens are transferred via the con- However, as to the poultry litter, it enters the cooking veyors to the evisceration stage (EV stage). In the EV stage where it is cooked for 2.5 hours. Then it leaves stage, the chicken’s head and feet are cut and removed, the system for cooling. Afterward, the yield is pressed and then the chicken is eviscerated automatically in a pressurized tank to produce the fat-oil for the fuel whereby the internal organs are mechanically removed burning stage. Fig. 2 shows the input-output process of using a device which is inserted into the opening and each process stage. the viscera are withdrawn. Another sucking system is used to take out the lungs and make sure that there are RESULTS AND DISCUSSION no blood and/or body liquids in the eviscerated chicken body. A water spray system is used to wash the eviscer- The cooked product contains 33 % (wt basis) of fat, ated chicken internally and externally prior to chilling. 65 % (wt basis) of protein, and 2 % (wt basis) of residual The chickens are unloaded, immersed and moved matter, which is finally pressed to produce fat-oil syrup through a counter-flow current in the pre-chiller followed of which 19 % (wt basis) is fat in average. The average by screw chiller at temperature less than 5oC. After that production of poultry from the slaughterhouse reaches the chickens are dried. Rehanging of chickens is manu- up to 150 tons/day of which 25 % is poultry litter (ap- ally conducted on moving conveyors which pass through proximately 37.5 tons of poultry litter per day). The air chilling room to reduce any contamination risk. The daily production of fat-oil syrup from the slaughterhouse chickens are then automatically weighed and classified ranges between 1,800 to 2,000 liters, while the daily (fresh and/or frozen chicken, wrapping, partitioning, quantity needed to meet all heating demands in the cutting, and de-boning). After weighing and grading, slaughterhouse accounts for 4,500 liters. The specific chickens are usually packed on polystyrene trays and gravity of fat-oil is 0.87 with a heat content of 35.30 wrapped with transparent film. Then the packed poultry MJ/kg (97 % of diesel heat content (36.4 MJ/kg lower products are cooled, frozen, and stored for shipping. heating value)). Table 1. Calculation for Fat-Oil Boiler. Fat-Oil Boiler Value Unit

Average Daily Poultry Production 150 ton

Percentage of Poultry litter (Heads, Feet, Intestine, 25.00 % Blood, and Feathers)

Daily Production of Poultry litter 37.50 ton

Average Daily Production of Fat-Oil 1,900 L

Fat-Oil Production per ton of Poultry litter 50.67 L/ton

Average Demand of Fat-Oil 4,500 L

Required Quantity of Fat-Oil (Shortage) 2,600 L

Required Quantity of Poultry litter (Demanded) 51.32 ton

Average Price per ton of Poultry litter 25.00 JOD

Average Daily Cost to Run the Fat-Oil Boiler 1,283 JOD

598 Motasem Saidan, Hussam J. Khasawneh, Mohammad Tayyem, Mohammed Hawari

Table 2. Calculation for Diesel Boiler. Diesel Boiler Value Unit

Daily Diesel Demand 3,500 L

Average Price of Diesel for the Year 2014 0.685 JOD/L

Average Daily Cost to Run the Boiler on Diesel 2,397 JOD

Table 3. Saving Calculation. Saving Value (JOD)

Average Daily Cost to Run the Fat-Oil Boiler 1,283

Average Daily Cost to Run the Boiler on Diesel 2,397

Daily Saving 1,114

The average price of poultry litter ranges between Using poultry waste as a feedstock to produce 20 - 30 JOD/ton, while the average price of diesel for the electricity and/or process steam requires specialized year 2014 is 0.685 JOD per liter. Therefore, by assuming equipment, designs, and practices, but is technically that no change occurs on diesel prices it is found that the feasible using currently available technology. One usage of poultry litter as a source of energy to run the major drawback associated with any feasible system is fat-oil boiler will result in a daily saving of 1,114 JOD. capital costs of the technology infrastructure and equip- Tables 1 and 2 show the findings of the data gathering ment. Normally, 3 to 5-year return-on-investment (ROI) and analysis for fat-oil boiler and diesel boiler, respec- is makes the project economically feasible. However, tively. Accordingly, the resulting savings of poultry currently there is no reported literature of an energy waste-to-energy are calculated as shown in Table 3. producing system in poultry business and industries that Figs. 3 and 4 show the variation in daily saving vs could provide enough adequate energy and would entail the poultry litter price and the diesel price, respectively. a 3 to 5-year ROI.

Fig. 3. Daily saving vs poultry litter price (at diesel Fig. 4. Daily saving vs diesel price (at poultry litter price price of 0.685 JOD/L). of 25JOD/ton). 599 Journal of Chemical Technology and Metallurgy, 52, 3, 2017

Another economic advantage of using poultry- CONCLUSIONS waste-to-energy is the utilization of the nutrient-rich ash which is expected to have significant value for use in This paper addresses a poultry waste-to-energy fertilizers. Phosphorus and potassium are the nutrients case that has many properties and attributes that are present in highest concentration. Internationally, the advantageous for a small-scale poultry litter to energy net fertilizer value of poultry waste ash at the energy production system. Moreover, of poultry plant, after accounting for transportation costs and any litter is considered as a solution to the issue of excess additional processing costs, will approximately range waste generation from industrial poultry operations. It between $25 and $75 per ton of ash [21]. was found that it becomes feasible to use the poultry As to the environmental impact of poultry waste- litter as an alternative source of energy if the price of to-energy process, the sources of emissions from this poultry litter is kept below 46.7 JOD per ton, assuming process include the smokestack effluent, truck exhaust that the price of diesel will stay on the (0.685 JOD/L). from transport of poultry litter and waste ash, runoff Moreover, the daily saving increases with decreasing from washing of the trucks, and disposal of the plant’s prices of poultry litter and/or decreasing diesel prices. wastewater. Incineration of organic materials produces Other economic viability of poultry waste-to-energy emissions, including particulate matter of varying sizes, process depends on being able to market poultry waste carbon monoxide (CO), carbon dioxide (CO2), dioxins, ash for use in fertilizers because of nutrient concentra- nitrogen and sulfur oxides (SOx), heavy metals, polycy- tion and value in the ash. clic aromatic hydrocarbons, and others, similar to those of other incinerators that use more conventional forms of REFERENCES fuel [22]. These emissions can individually and jointly impact both the environment and human health [22 - 24]. 1. F.A. Vollenbroek, and the Hence, the processes and emissions related to alterna- challenge of innovation, Journal of Cleaner Produc- tive energy sources require detailed scrutiny to prevent tion, 10, 3, 2002, 215-223. sacrificing the communities’ health and environment. 2. W. McDonough, M. Braungart, The next industrial Moreover, biosecurity measures are required in poultry revolution, The Atlantic Monthly, 282, 4, 1998, 82- waste-to-energy projects, and regulations should be set 90. for achieving biosecurity. 3. S. Schmidheiny, Changing course, Cambridge, MA, It is worth mentioning that the poultry waste-to- MIT Press, 1992. energy process is subject to environmental impact as- 4. E. Ciccozzi, R. Checkenya, A.V. Rodriguez, Recent sessment (EIA) regulations in Jordan. This is in order experiences and challenges in promoting cleaner to mitigate all environmental impacts that might be production investments in developing countries, caused by such a process. However, previous studies Journal of Cleaner Production, 11, 6, 2003, 629-638. showed comparison of emissions from controlled coal 5. G. Kjaerheim, Cleaner production and sustain- and biomass combustion and poultry litter processes and ability, Journal of Cleaner Production, 13 2005, mainly focusing on the emissions from the smokestack 329-339. [25]. The results of comparison analysis showed that 6. S. Sangwon, L. Kun Mo, H. Sangsun, Eco-efficiency plants fueled by poultry litter are permitted to produce for pollution prevention in small to medium-sized more carbon dioxide than other forms of fuel and more enterprises: a case from South Korea, Journal of carbon monoxide than either new or existing coal plants. , 9, 4, 2008, 223-240. They are also permitted to produce more NOx than new 7. R. Van Berkel, J. Kortman, Waste prevention in coal plants, and more SO2 than plants which use new small and medium sized enterprises, Journal of wood or existing biomass to create electricity [25, 26]. Cleaner Production, 1, 1, 1993, 21-28. Nevertheless, the EIA shall be conducted for such type 8. R. Van Berkel, Introduction to cleaner production of processes in order to resolve all potential negative assessments with applications in the food processing environmental health impacts of incinerating poultry industry, UNEP Industry and Environment; January/ litter for the purpose of energy generation [25]. March. p. 8-15. 1995. 600 Motasem Saidan, Hussam J. Khasawneh, Mohammad Tayyem, Mohammed Hawari

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