MotasemJournal Saidan, of Chemical Hussam J. Technology Khasawneh, and Mohammad Metallurgy, Tayyem, 52, 3, 2017, Mohammed 595-601 Hawari GETTING ENERGY FROM POULTRY WASTE 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 Climate Change (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 litter 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 pollution prevention and energy conservation 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 pollution prevention 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. wastes 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 waste management 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- population growth, 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 air pollution 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 water pollution (from leachate 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 plastic 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.