The works performed once the slaughterhouse was selected, were to design the equipment where the process of transforming the hair into fuel would be carried out, since it should be adapted to the real needs of slaughterhouse. Then we had to perform the same tasks in the steam generator, hair storage hopper and fuel storage tanks.
Once the main elements of the installation were designed and dimensioned, and taking into account where we should locate the equipment, we began to design the layout of the installation. Finally, we installed lines of fluids and machines according to the planning made. The results obtained were the following, based on the objectives set:
A) Objective nº 1. To demonstrate that pig hair could be transformed into fuel on an industrial scale, and that its production presented no problems. Once the installation was finished, and all the relevant tests were carried out, the first of the tests was done with half load. With the experience we had in the laboratory, we performed the same type of process, and fortunately the result was identical. A dry fuel, and as we could see later, of high calorific value was obtained.
B) Objective nº 2. To prove that the heating power of the fuel is high. With the first samples, the Univeristy of Vic came on the scene. Being able to check the calorific value of the product obtained was very important. The results obtained in the laboratory of the University of Vic were satisfactory. The calorific value was 4300 Kcal/Kg, a really high value!
c) Objective nº3. To prove that the fuel burned correctly in an industrial steam generator, and that the combustion presented no later problems. We proceeded with the first combustion tests. As a preliminary step, and in order to safeguard the fuel obtained, we loaded the biomass silo with wood chips, which led us to test the entire truck unloading system too. We wanted to make the appropriate adjustments in the steam boiler itself. We had to test the equipment, and for that we carried out the combustion and preheating tests of the firebox with biomass, to have everything ready to be able to focus on the tests with pig hair.
Once the parameters were achieved and adjusted properly, we could go in search of checking if we could meet this third objective. The tests were performed with the fuel and biomass. Once these tests were finished we look at the tubular plate and the mobile grills, without any sign of ashes stuck.
D) Objective nº 4. To prove that levels of emissions resulting from the combustion were within the parameters required by the regulations in force throughout the EU (some of the most demanding worldwide). Scientists from the University of Vic visited the installation, this time accompanied by a specialist in measurement of combustion gases. The measurements had to be taken under optimal working conditions. Prior to the measurement there had been a meeting between the University of Vic and our technicians, in order to analyse the requirements of the regulations in force, and decide which parameters should be measured. Once the tests were over we were able to receive the complete report, the results were unbeatable. The goal was fulfilled.
E) Objective nº 5. To prove that the production of this fuel was economically viable, amortizable within a reasonable period of time. The use of PIGHEAT technology does not increase the energy cost of the slaughterhouse operation, but rather the opposite: It saves the costs of hair collection as a by-product by an external company, and provides the industry with more energy than needed to process it. It also reduces the carbon footprint, since it eliminates the amount of fossil fuels that these companies consume. Also using, as has been developed in the pilot plant, an exchanger that recovers the latent heat of the evaporated water from the hair, the energy saving is even greater.
After the tests, we calculated that the payback period for a standard plant for such capacity would be in the worst case 6.3 years (gas) and less than 3.6 years for light oil. With these results we are satisfied. We have achieved all the objectives that we had initially set ourselves, and we have demonstrated what at the laboratory level convinced us and the European Commission two years ago, and that served us to be worthy of receiving their trust. Pig hair, which until now was a waste without any value, can already be considered one of the main assets of slaughterhouses, and will no longer represent an environmental problem.
