From the Yorkshire Water website, an article about one of our AJ Tensile Biogas Systems gasholders which was manufactured by sister company AJ Tensile Manufacturing Ltd. The photos were unfortunately taken before it was cleaned – the dirt accumulated because it had to be left uninflated for a short while exposed to typically British weather..!
Swinging into action – poo power helps Yorkshire Water drive green ambitions at Knostrop
Those who drive into Leeds on the M1 or A63 may have seen a rather large golf ball looking object appear on the Yorkshire Water Knostrop treatment plant near Leeds.
The firm is not trying to create a mini Epcot Centre in Leeds, but building a gas bag, with its construction meaning another landmark has been reached in the £72m project.
Methane produced from sludge treatment will be stored in the bag with up to 3,700 cubic metres of gas stored at any one time. All of this gas will then be turned into electricity to help power the plant.
The facility will begin processing in August and once fully operational later this year, will contribute significantly to the recycling of 94% of Leeds’ sewage sludge by 2020.
The facility will be capable of processing up to 131 tonnes of dry sludge a day and will generate enough renewable energy, using heat and power engines, to provide 55% of Knostrop’s energy needs – enough to power 8,000 homes.
Yorkshire Water Project Manager, Lee Laherty, said: “This is the single biggest investment the company is making between 2015 and 2020.
“The installation is a huge deal because we can start creating more electricity for ourselves and do more to reduce carbon emissions and help the environment.
“It also supports Leeds council’s ambition for the Lower Aire Valley to become a hub for green energy and industry.”
Mounted on a 3m concrete plinth, this 4,000 cubic metre BioSphere gasholder was recently installed by our installation crew at Knostrop Sludge Treatment Facility in Leeds for Yorkshire Water Services Ltd. With a base diameter of nealy 18m and a height of around 15.5m, this BioSphere is an imposing structure that requires expert installation techniques and takes around six hours to inflate once secured to the plinth. All production was performed in-house by AJ Tensile Manufacturing Ltd at our facility in Caldicot, with design, project management and installation performed by AJ Tensile Biogas Systems Ltd. Additional volumetric checks were performed on-site after inflation to confirm the accuracy of the level-checking laser by measuring discharged air using an anemometer.
AJ Tensile Biogas Systems Ltd recently completed a 2,500 cubic metre Biosphere for export to Pontiac, Michigan in the USA. Constructed using our double-skin membrane design and with an operating pressure of 20 millibar, this tank-mounted gasholder will stand around 10.5m high when fully inflated and was fabricated in-house by our production division, AJ Tensile Manufacturing Ltd.
The Special Projects division of A J Tensile Manufacturing Ltd recently completed a prestigious staging installation for one of our major clients. Consisting of two 60m arched trusses with an octagonal suspended roof over a raised stage, the structure was one of seven temporary staging installations for the All Points East Festival in Victoria Park, East London. Our fabric panels provided cover and backdrop for the lighting arrays built into the arches.
We had to work to a very tight schedule but our client was very pleased with the final result, saying “A J Tensile did it again, managing to deliver as always, despite the late information”.
This slab-mounted 400 cubic metre BioSphere gasholder was designed and project managed by our Biogas company and fabricated by our Manufacturing division for a client in Jakarta, Indonesia. This is the first BioSphere that we have produced for the Indonesian market and it had to be manufactured to a very tight program so that five weeks of port-to-port sea delivery could be achieved. Installation will be performed by the client under the direct supervision of one of our senior installers.
Our Biogas division recently completed one of the smallest gasholders we have ever produced for a client in Ontario, Canada. Measuring just 50 cubic metres and standing around 4m tall, the double-skinned slab-mount Biosphere was awarded to us by our North American licensee and manufactured in-house by our Manufacturing division before being carefully packed and crated for export.
Our Biogas and Manufacturing divisions collaborated recently to complete a 975 cubic metre Biosphere gasholder at Sandown on the Isle of Wight for Southern Water and Barhale Trant Utilities LLP. This was to replace an existing unit that had come to the end of its long and happy life, and our new design offered improvements by having no gap between the inner and outer membranes.
The installation went smoothly despite adverse weather conditions where the whole site was blanketed in thick snow, and our installation crew worked closely with the client to ensure that delays were kept to a minimum. The gasholder went into full operational service only a week after the installation was completed.
Our Biogas and Manufacturing divisions recently completed a joint Biogas project in the USA for WesTech Engineering. Located in Rahway, New Jersey, the tank-mounted BioSphere gasholder has a capacity of 1,350 cubic metres with a base diameter of over 23m and a height of over 6m. This project is the first of three phases for Rahway Valley Sewerage Authority, an autonomous agency that owns and operates a trunk sewer system and a wastewater treatment facility in Rahway, New Jersey. The RVSA currently serves more than 250,000 residents and 3,500 industrial and commercial customers in 14 communities in central New Jersey.
AJ Tensile Biogas Systems and AJ Tensile Manufacturing Ltd will also be manufacturing BioSphere gasholders for Tank No.2 and Tank No. 3.
A hands-on site supervisor is required to oversee installations of biogas domes and anaerobic digester covers. No experience is necessary as full on-the-job training will be provided. Must be willing to work away from home occasionally for several days at a time and be capable of using hand tools (drills and spanners etc). CSCS certification is a requirement, experience with MEWPs would be beneficial. Please send your CV with a covering note to email@example.com
The £60M scheme changes the way the company treats waste before generating green power and will make the process considerably more efficient, meaning the amount of clean energy generated will increase by almost a third. More than half of the plant is now up and running and it is expected to be fully operational by the end of the summer.
Severn Trent said the Minworth site already generates enough clean electricity to power the equivalent of 11,000 homes and enough gas to heat 4,800 homes every year, with this set to increase as the THP comes online.
David Nyul, who is leading the project for Severn Trent, said: “It’s really exciting to see this cutting edge technology starting to become operational.
“This has been a huge investment for us and this innovative tech means that we’ll be generating more green power than ever before at Minworth. We have significant expertise in anaerobic digestion and THP is the next step to make the process even more efficient in the future.”
The process works by heating sewage sludge to 170°C and then pressurising it. The thermal hydrolysis process has an additional benefit as the leftover solids can be classified as “enhanced” status fertiliser and could potentially be used in the production of crops for human consumption, Severn Trent said.
Nyul added: “Minworth is our biggest sewage works and treats waste water from more than 1.6 million homes and businesses across Birmingham and the Black Country. The technology we have already generates both power for use in the works and gas for injection into the national grid.
“The bio-gas we create through this process will both be used to generate electricity and to be treated at our gas to grid plant on site to make it suitable for domestic use before being injected into the grid where it will be used by local homes and businesses.
“The new THP will increase our generation which is good for Severn Trent, for our customers and for the environment.” Severn Trent aims to generate 50 per cent of the energy it uses by 2020.
The company announced plans to invest £100 million to “get ready for the future” as it posted its latest set of financial results on 23 May.
Author: James Brockett, Water & Wastewater Treatment newsletter