References

The design was carried out in partnership with Magen. Compact and resource-efficient solutions were implemented for the main process areas: steam consumption is 17 kg/dal, electricity consumption is 2.6 kW/dal, and water consumption is 50^m³/h. The use of the latest yeast strains and enzymes has increased the mash strength to 14%. The purity of the bioethanol (99.93% Et.) is ensured by Magen molecular sieves.

Construction of the plant took 18 months. In addition to serving as the general contractor for design and construction, UTC manufactures 80% of the equipment for the five production units. A molasses storage facility, a piping system, a recirculating water supply unit, and a finished products warehouse have been built. The plant has been in operation since 2016. It processes molasses and diffusion juice into bioethanol with a purity of 99.93% Et. It operates 24 hours a day, 305 days a year. The number of employees per shift is 25. Bioethanol production amounts to 1,830,000 dal per year.

Pannonia Bio, Europe’s largest biorefinery—founded in 2012 and located on the banks of the Danube near the city of Dunafeldvar—is one of the most efficient and environmentally friendly facilities in the world. In 2015, UTC was tasked with designing, manufacturing, and installing equipment for the rectification, dehydration, and DDGS production lines based on engineering specifications provided by Magen. As a subcontractor, UTC custom-manufactured 70% of the equipment for the DDGS plant and installed 100% of all equipment for the processing section, which has a capacity of 850 metric tons per day. The construction site covered 8 hectares, and the total weight of the steel structures and equipment was 2,500 metric tons.

Following the expansion, the plant tripled its production. Each year, it processes 1.1 million metric tons of feed corn to produce 325,000 metric tons of protein feed for animals, 500 million liters of bioethanol, and 12,000 metric tons of corn oil. Pannonia Bio is a subsidiary of ClonBio Group Limited, an Irish agricultural company headquartered in Dublin.

Dionis Biogas Energy Biogas Power Generation Complex

The complex was designed using ADVERIO’s Dutch zero-waste anaerobic digestion technology.
Preliminary methanation tests were conducted by Opure (Netherlands). The technical solution includes two Methantank reactors:
an industrial anaerobic digestion reactor 21 m high with a volume of 8,000^{m³, and} an agricultural reactor
—a digester-degasser 10.5 meters high with a volume of 4,000^m³.

The work lasted 18 months. More than 60% of the biogas equipment—including anaerobic digestion reactors, mixers, agitators, heat exchangers, conveyors, screw conveyors, dewatering units, flotation units, scrubbers, filters, and boilers—was designed under license and manufactured at UTC’s own production facility, KEMP. Manufacturing a portion of the equipment directly in Ukraine reduces capital investments, recoups 10% of the equipment cost, and increases the “green” tariff rate to 136.3 EUR per MW for the next 5 years.

The final stages of the project included piping, automation, commissioning, and staff training. The facility has been in operation since November 2019.

Processing of 85 metric tons of beet pulp and 115 metric tons of silage per day. Operations run 24 hours a day, 365 days a year. Number of employees per shift: 5. Biogas production: 1,350^m³/hour; electricity generation: 3.2 MW; dry cake production: 40 metric tons per day. The construction of the second phase of the YUMBK is
UTC’s current project.

The complex was designed using ADVERIO’s Dutch zero-waste anaerobic digestion technology.
Preliminary methanation tests were conducted by Opure (Netherlands). The technical solution includes: 4 high-capacity industrial methanation reactors, 25 m tall and with a volume of 8,000^{m³, and} 2 agricultural digesters, 10.5 m tall, with a volume of 4,000^m³.

Construction took 24 months. More than 60% of the biogas equipment was manufactured by UTC. Anaerobic digesters, mixers, agitators, heat exchangers, conveyors, augers, dewatering units, flotation units, scrubbers, filter cartridges, and boilers were designed under license and manufactured at KEMP—the company’s own production division.

The biogas plant processes 1,200 metric tons of beet pulp per day, 225 metric tons of sugar beet leaf silage, and manure from the pig farm.
It operates 24 hours a day, 150 days a year. There are 12 employees per shift.

It produces 150,000 m³ of biogas per day—the equivalent of 75,000 m³ of natural gas. During the sugar processing season, biogas provides 50% of the total industrial heat for the Globyne Sugar Plant. At the end of the season, the biogas is supplied to the Globyne Soybean Processing Plant.

From April through September 2018, the Gnidavsky Sugar Factory completed the renovation of its beet processing unit, including the installation of PB22S-type pulp presses manufactured by Babbini (Italy). Capacity: 7,000 metric tons per day.
Raw materials: Fresh beet pulp accounts for 90% of the beet’s weight; the daily processing capacity is 6,300 metric tons. The sugar content is 6%.
After pressing: the amount of pressed pulp was 1,575 metric tons. The dry matter content was 24%.

The beet pulp drying complex at the Khorostkiv Sugar Plant, part of the “Mriya” agricultural holding, was designed using French Magen technology. UTC also carried out the construction, manufactured the equipment, and commissioned the facility. High-temperature drum drying of beet pulp on a wire mesh conveyor produces a final product with a dry matter content of 90% from raw material with a moisture content of up to 80%. After drying and pelletizing, beet pulp becomes a valuable animal feed.

The plant is capable of processing 40 metric tons of pulp per hour, providing a daily output of 300 metric tons of pelletized dry feed. During the spring and summer, it is possible to switch to alfalfa as the raw material. All technological processes are fully automated. The pellet diameter is 8 mm. Coal consumption is 0.36–0.43 metric tons per metric ton of pellets.

The complex consists of an open-air coal storage yard, a gallery for feeding pressed pulp, an open-air industrial site, a control room, a technical facility, an open-air ash storage yard, and a daily storage yard for finished products. Provision has been made for shipping finished products by rail and truck. The drying complex has been in operation since 2013. Since 2017, the Khorostkiv Sugar Plant has been owned by Radehiv Sugar LLC, a subsidiary of the German company Pfeifer & Langen.

The “Gek-Gel” Plant is a modern agro-industrial enterprise with integrated production facilities for wine, spirits, cognac, champagne, and non-alcoholic beverages. In 2016, following a successful collaboration on the construction of a distillery using zero-waste technology, the company approached UTC with the task of recycling excess wine pomace and acidic condensate from the DDGS production facility. Tests revealed a high concentration of suspended solids at 2,000 mg per liter and very high COD and BOD levels. The problem was resolved using a compact combined aerobic-anaerobic treatment solution, which removed 98% of the contaminants. Specifically, the COD values are as follows: inlet—10,000 ppm, outlet—30 ppm.
Configuration of the treatment system: Flotation unit – MBBR – IC – Settling tank. The treatment system has been in operation at the facility since 2017.

As part of the construction of Roshen’s new dairy plant, UTC was entrusted with the design and construction of the wastewater treatment plant. The plant’s effluents have a high concentration of fats and oils, exhibit temporal and daily variations in discharge volume, composition, and _pH, and require emergency discharges of “reject milk.” In other words, the composition varies significantly, and the COD load can exceed the daily limit by several times.

To ensure a consistent level of treatment and uninterrupted operation even during emergency discharges, UTC has implemented a six-stage treatment system. The technology is based on denitrification and aerobic treatment using a high-load MBBR reactor with immobilized biomass and a flotation unit. The design and construction period lasted 12 months. The wastewater treatment plant has been operating 24 hours a day, 365 days a year since 2014. COD removal rate: 98%.

The plant processes 600 metric tons of milk per day. The treatment facilities have a daily capacity of 1,300 cubic meters of wastewater.
The pollution levels at the outlet are below the water utility’s standards.

The company is nearly 90 years old and has been in operation since 1936. It is the leading company in Belarus’s hydrolysis and microbiological industries. Specialization: food-grade and industrial-grade ethyl alcohol, industrial solvents and cleaning agents, antifreeze, feed proteins, medical antiseptics, and biological plant protection products.

In 2014, UTC was tasked with effectively resolving the issue of disposing of grain and molasses stillage effluent. This involved daily peak organic loads and high concentrations of suspended solids, with COD at 30,000 mg O₂/L and BOD. As a result, an anaerobic treatment system was implemented to produce biogas. The system is based on two high-load UASB reactors. The COD removal rate is 85%. Biogas production is 230 m³ per hour. The treatment system has been operating continuously and has been handling peak loads since 2014.

A Nestlé Group company that produces mayonnaise, ketchup, and sauces. In 2011, UTC was tasked with a comprehensive renovation of the plant’s wastewater treatment facilities without halting production or reducing capacity. Tests revealed high concentrations of fats, COD, and BOD in the wastewater. Discharges were inconsistent in terms of volume, composition, and pH, with significant variation in the COD:N:P ratio. The successful solution was the use of a continuous-flow aerobic MBBR reactor with immobilized biomass combined with a flotation unit.

The design and construction period lasted 12 months. The project was completed without any downtime or reduction in the plant’s capacity.
The treatment plant has been operating 365 days a year, 24 hours a day, since 2011. Its average daily capacity is 190 m³ per day.
The maximum is 350 m³ per day. The treated effluent meets all discharge standards set by the municipal water utility.

In 2008, the “Dairy Alliance”—which brings together nine companies involved in the production and sale of cheese—acquired the Bashtanka Cheese Factory. The company’s biggest problems stem from its wastewater discharge. The company regularly pays fines, and the Ingul River is being polluted. The plant’s wastewater has a high concentration of fats and oils, and the company lacks sufficient space for settling ponds. Opure, Adverio, and UTC have proposed an aerobic-anaerobic treatment technology that produces biogas to the owners.

Technical solution: Flotation unit – UASB reactor – Settling tank – MBBR reactor. In addition to treating the effluent to meet regulatory standards, 100% of the energy consumption is covered by heat generated on-site from biogas production.

This is UTC’s first biogas production project at LOS. A byproduct of the treatment process is cake—an organic biofertilizer. LOS is a completely waste-free facility that operates using recycled wastewater. Result: 95–97% removal of organic pollutants and 80% removal of phosphorus compounds.

The design and construction took 18 months. The wastewater treatment plant has been in operation since 2009 at a capacity of 1,300 m³ per day. In 2011, the project won third place at the Green Awards Ukraine in the “Best Project in Water Supply and Wastewater Treatment” category.

In 2014, as part of the expansion of the Khanlar Agricultural Complex UTC, UTC completed the design and construction of a new, state-of-the-art Gekgel distillery for the production of rectified ethyl alcohol from grain.

A unique zero-waste technology has made it possible to produce 3,000 dal of alcohol per day. At the same time, 30 metric tons of DDGS—a valuable dry feed—are produced through the drying of the distillers’ grains that accumulate during the alcohol production process. The compact DDGS plant facilities were built on a 0.05-hectare site at
, and the total weight of the steel structures and equipment was 600 metric tons.

From a byproduct of fermentation, 20 metric tons of liquid carbon dioxide (CO2) with a purity of 99.99% are produced. This meets the demand for carbon dioxide for the company’s own production of champagne and non-alcoholic beverages. Surplus CO2 is sold to other soft drink manufacturers. The Hekhelsky Plant is part of the VinAgro group of companies. The company exports 25 varieties of wine, cognac, champagne, and vodka to Ukraine, Russia, Belarus, and China.

In 2005, the winery underwent a complete renovation and was technically upgraded. The next stage in the development of production was the establishment of the company’s own competitive production of high-quality food-grade alcohol. UTC served as the general contractor for the design and construction of a new production facility for rectified ethyl food-grade alcohol, which serves as the base for vodka and cognac.

The plant has implemented energy-saving technologies for water, steam, and electricity. All production processes are fully automated. The distillery has been operating successfully since 2006. Today, Gyanja Sharab-2 is a modern, full-cycle production facility. The company’s portfolio includes more than 40 brands.