References

As a subcontractor, Magen custom-made 70% of the equipment for the rectification, dehydration, and DDGS units.

• The construction and installation work covers 8 hectares.
• The total weight of steel structures and equipment is 2,500 metric tons.
•  After the expansion, the processing area capacity is 850 metric tons per day.

Adverio biogas production technology .

• Feedstock: waste from sugar and alcohol production elevators.
• End product – biogas/electric energy/organic fertilizer
• Production capacity: 750 m³ of biogas/h, 1500 MW/h, 60 tons/ per day.
• Configuration: 1× 8,000 m³ + 1 × 4,000 m³.

Phase 1/2019: Anaerobic digestion technology Adverio

• Feedstock: sugar production waste
• End product – industrial heat , electricity, solid fertilizer.
• Production capacity: 2500 m³ of biogas/day, 3200MW/h, 200 tons per day
• Configuration: 1 × 8,000 m³ + 1 × 4,000 m³.
• Loading: 24 hours/335 days per year.

Phase 2/2022: Anaerobic digestion technology Adverio+biometane technology Aerco

• Feedstock: sugar production waste and prepared straw
• End product – industrial heat , electricity, biometane, solid fertilizer.
• Production capacity: 2500 m³ of biogas/day, 10000MW/h, 200 tons per day
• Biogas purification to biomethane using amine adsorption technology
• Configuration: 2 × 8,000 m³ + 1 × 4,000 m³+ 1× 6000+ 2 bioscrubbers +1ammonia plant
• Loading: 24 hours/335 days per year.

   

                  Anaerobic Digestion Technology Adverio.

• Feedstock: beet pulp, silage, pig farm manure.
• Processing capacity: 1,425 metric tons of feedstock/day
• Production capacity: 150,000 m³ of biogas/day 
• Loading: 24 hours/150 days per year.
• End product – industrial heat
• Configuration: 4 × 8,000 m³ + 2 × 4,000 m³.

Modernization of the workshop, including the installation of PB22S type pulp presses, Babbini (Italy).

• Feedstock: Fresh beet pulp.Dry matter content – 6%.
• End product – pressed pulp. Dry matter content – 24%.
• Processing capacity:
• Production capacity:  – 1,575 tons/day.

• High-temperature drum drying of beet pulp using Magen technology.
• Feedstock: Pulp moisture – up to 80%. Alternative raw material – alfalfa.
• Coal consumption – 0.36–0.43 tons per ton of granules.
• End product – DDGS granulated pulp 8 mm. Dry matter content – 90%.
• Production capacity: 40 metric tons/hour . 300 metric tons of DDGS/day.
• 100% Automation.

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.