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Development of A Technology Solution For Cooling of Milk by Biogas in Farms
Development of A Technology Solution For Cooling of Milk by Biogas in Farms
Abstract— This article describes the adaptation process to improve the producers ́ milk trading capacities, facilitating
from milk cooling machines powered by electricity to cooling them to trade in the formal market and; to increase farms ́
machines powered by biogas. Modifications to manufacturer`s productivity with the possibility of a second milking session.
cooling machines included the combustion engine ignition These kinds of technological improvements empower small
system, the replacement of electric compressors by mechanical producers in rural areas who face difficult access or mobility,
ones, and the electrical and control systems. Once the changes
were implemented, a series of laboratory tests were performed.
with weak or no electricity services, to meet the requirements
The tests covered the following parameters: speed (ºC/h), of national dairy industries, and improve their competitiveness
cooling time (hours), biogas consumption (m3/hour) and cooling simultaneously [4].
system efficiency. Minimum differences were obtained when the
manufacturer ́s parameters were compared to the laboratory II. IMPLEMENTATION OF THE PROJECT
tests results. The field validation was done from May to October A. Backgrounds
2018. Two machines were installed in one farm in Jinotega and
the other one in a farm in Matagalpa. Currently, two of them The electric energy required to cool down 500 liters of milk
are fully operating. Average values of the final results ranges between 6.5 and 8 kWh, which is difficult to obtain
(combining laboratory and field results) were: Cooling Time from small electric generators powered with biogas due to the
2.59 hours, Cooling Speed of 11.62 °C/h, Biogas Consumption loss of efficiency of some components like the combustion
rate of 1.6 m3/h, and an efficiency of 33%. These results allow engine, the electric generator, the compressor electric engine,
to conclude that the use of adapted cooling machines fueled with and the compressor itself. Also, it is important to note that
biogas in farms is a feasible technical solution. It is estimated there are efficiency limiting factors of the cooling machines
that the investment recovery for this project is two years.
like the low heating power of biogas (combustion), the blend
composition (methane and other gases), and the input-time
Index Terms: Milk, biogas, machine, temperature, adaptation,
cooling. pressure changes of biogas. All these factors severely affect
the performance and the energy supply of cooling machines
I. INTRODUCTION [4].
In Nicaragua the dairy sector produced around 769 million B. Development Method
gallons of milk in 2014 [1]. These results show a 37.3% Former attempts to use biogas in cooling machines had a
growth, taking year 2000 production as the baseline. significant efficiency loss caused by the following
According to the same source, in 2015 Nicaragua has exported components: the Otto engine, the electricity power generator,
202 million dollars. It is estimated that almost 70% [2] of the compressor electric engine, and finally the cooler
producers are part of the informal dairy market in Nicaragua. compressor itself, all these weaknesses lead to a non-viable
These producers do not have a cold chain that ensures them to system for the milk´s cooling. [4]. ULSA ́s proposal
comply with the quality standards demanded by the industry simplifies and improves the efficiency of this chain by
and formal markets. The quality of milk decreases reducing it into two components: the Otto engine, and a
exponentially if it is not cooled down to 4º C at the milking mechanical compressor. This reduction of components leads
farm [3]. Additionally, the combination of distant locations of to a significant increase of the overall system performance.
farms and the lack of proper maintenance of roads, mainly in This approach allowed a direct drive of the refrigeration
winter, does not allow the producers a timely delivery of their compressor by the Otto engine running on biogas.
milk production to collection points or cooling centers.
The replacement of the electric compressor by a mechanical
In this context, La Salle Technological University (ULSA one generated the necessity to do thermodynamic
acronyms in Spanish) along with the Netherlands calculations, in order to measure entirely the cooling system
Development Organizations (SNV) carried out a project to [5] and to determine the capacity of the open-compressor to
adjust milk cooling electric machines to be fueled with biogas. be used. Three volumes of liquids to be cooled off were
The main objective was to provide a technological option for considered (150, 250, 500 liters), the operating temperature
cooling using local biofuels, in this case biogas, from the start range was established between 36°C to 4°C and the operating
of the cold chain at the farm site. time ranged from 1 to 3 hours. The resulting open-
This modification allows: To increase the use of coolers at compressors have a volumetric displacement of 2.38 m3/hour
farms without the use of electricity; to reduce energy costs, (IY) and 3.32 m3/hour (IIY) [6], both with capacities to work
rejection or fines due to the low quality of the milk delivered; with 300 and 500 liters respectively.
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Three different brands of Otto engines (gasoline) were compressor, which is powered through an internal
selected to operate the mechanical compressor. The Otto combustion engine that uses biogas energy for its operation.
engines were firstly fueled with gasoline and then with
A. Technical Adaptation
biogas, the one that enabled the compressor to operate more
efficiently was selected. All of them share the same feature. In general, the components of the adapted (CM1 and CM3)
Their (adapted) carburetors are capable to work with cooling machines (CM) are: a) Cooling tank, b) Control
gasoline, liquefied gas (LPG) and biogas. When the change Panel, c) Fans, d) Agitator, e) Battery 12 V, f) Alternator, g)
from gasoline fuel to biogas was made in the first Otto engine, Compressor-Opened, h) Pulley System, i) Motor, j)
the operating conditions of the engine varied, reducing its Condenser, k) Expansion Valve, l) Bronze Tubes, m) Support
power by 41.8%, the operating temperature of the cylinder Structure, n) Coolant Tank (See Figure 2 ).
head 1 increased 28ºC, and the consumption of biogas The main changes of system components consisted of: the
increased to 480 Liters/hour. This problem was solved by substitution of the electric compressor by a mechanical one,
modifying the angle of progress of the engine 2 [7] by 25º, the electrical system changed from 220V AC to 12V DC, the
obtaining remarkable improvements in its operation. control system, the condenser fans, the stirrer’s electric
C. Design Requirements for Cooling Machines motor changed from 220V AC to 12V DC, the capillary tube
was substituted by an expansion valve, the electric
Based on the producers ́ needs, the design requirements
compressor engine by an Otto engine, the coolant tank, the
are:
condenser, and a 12V DC generator (alternator) were added
a) Two daily processes of milking and 12 hours of along with an 80 Ah battery to store energy during the
storage-time until delivery. cooling process.
b) Three hours maximum time to cool down the milk
from 36º to 4ºC.
c) Storage tanks must keep stable temperatures (4°C)
until delivery.
d) In order to maintain the emulsion and milk
temperature stable in the storage tanks, they must have
stirrers.
e) The energy used in the stirring process must come
from batteries charged by a 12V alternator along the
cooling process.
f) When the cooling temperature reaches 4º C, the
system must stop and stir it automatically.
g) The system must be electrically autonomous, using
only the energy from biogas.
IV. RESULTS
Fig. 3. CM1 Design Representation for 300 litters.
In order to use the biogas energy, the cooling machine´s
electric compressor was replaced by a mechanical open-
1 2
Cylinder head: upper part of the cylinders that seals the combustion Angle of progress: Turning angle of crankshaft where combustion starts.
chamber.
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Test 1.3: The engine fueled with biogas was tested with a
displacement of 25 degrees in the angle of the modified
ignition system.
Fig. 4. Representation of CM2 factory design for 500 litters. C.2 Cooling Tests
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190 191
170 169
150
130
110
1400 1900 2400 2900 3400
Engine Spinning Speed (RPM)
Gasolina a 0° Biogás a 0° Biogás a 25°
Fig. 8. Variation of Biogas Consumption vs Engine spinning
Fig. 6. Variation of Engine temperature vs Engine spinning speed After the modification of the engine ignition system, the
biogas consumption rate was reduced by 480 liters/h (15.7%)
When the type of fuel was changed from gasoline to biogas in comparison with the consumption obtained without
(0º progress angle), the temperature of the Otto engine modification (see red line of the graph in Figure 8).
increased by 28ºC, which represented a rise of 14.6% in D.2 Test Results of the Cooling Machines
relation to the gasoline operating temperature; see red color Test results of cooling machines are shown in Table 2
line of the graph in Figure 6. This represented a high risk of
engine overheating when running with biogas. In order to Base Average
Parameters CM1 CM2 CM3
solve this problem, the ignition system was modified by Line (Biogas)
moving forward the ignition advance angle from 0° to 25° of Cooling time
2.42 2.74 2.75 2.45 2.59
crankshaft rotation 3 . After the modification of the ignition (h)
system (progress angle at 25º), the engine reduced its Cooling Speed
12.45 10.95 10.91 12.16 11.62
(ºC/h)
temperature to 22º C (11.5%) compared to the temperature
Biogas Cons.
obtained with gasoline. See green line of the graph in Figure 0.97 1.81 2.02 N/A 1.6
(m3/h)
6. Gral. Efficiency
0.39 0.31 0.28 N/A 0.33
of the System
ELECTRICITY POWER Table 2. Test results of Cooling Machines with 50% load capacity and using
biogas
2650 2625
Figures 9, 10, 11 and 12 show the Table 2 results in a
ELECTRICITY POWER (W)
650
150
1400 1900 2400 2900 3400
Engine Spinning Speed (RPM)
Gasolina a 0° Biogás a 0° Biogás a 25°
3
Crankshaft: main shaft of the internal combustion engine that receives
the movement of the connecting rods and transmits them to the steering
wheel.
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Summary Results
CM1-150 l CM2-250 l CM3-250 l
per Load
Cooling Time (h) 2.417 2.750 2.740
Cooling Time per
0.967 0.660 0.658
Milk´s Liter (min/l)
Cooling Speed (˚C/h) 12.447 10.913 10.95
System Efficiency
39.27% 28.17% 31.67%
(%)
Biogas Consumption
0.972 2.018 1.805
(m3/h)
Biogas Consumption
per Milk´s Liter 6.479 8.073 7.220
Fig. 11. Biogas Consumption Results for different machines. (lg/lm*h)
h = hour; min/l = minutes per liter; ˚C/ h = Celsius Degrees per Hour;
CM1 succeeded to reduce biogas consumption rate by 1.05
Efficiency is the amount of energy used to extract heat from milk; m3/h =
and 1.11 m3/h compared to CM2 and CM3 machines cubic meter per hour; lg/lm*h = Liters of Biogas per liter of milk per hour.
respectively (See Figure 11). Table 3. Summary of CM1, CM2 and CM3 Cooling Tests
V. FINANCIAL SCENARIO OF COOLING MILK USING
BIOGAS
The financial scenario carried out by SNV, consisted in the
estimation of investment costs, operational expenses and
estimated income produced by cold milk sales, energy
savings, and current maintenance. With this data, a cash flow
for a four-year period was calculated in order to determine
the return on investment of a cooling system powered by
biogas.
Financial results are positive. Data shows that to install, adapt
Fig. 12. General Results of the System Efficiency. and run a milk cooling system fueled with biogas (i.e. 300
liters cooling machine) gives an investment recovery period
The efficiency was calculated by dividing the amount of of two years, because it will generate US$ 2,810.25 [4] as
energy extracted from the milk in the form of heat [8], accumulated income.
between the amount of energy entered with biogas. CM1
exceeded the CM2 and CM3 machines by 0.11 and 0.08, (see VI. CONCLUSIONS
Figure 12).
Adapting a milk cooling system, that uses biogas as the main
Figure 13 shows an image of CM1 after adaptations in the fuel, contributes to increasing the competitiveness of the
Laboratory dairy sector, and improves the quality of dairy products
produced by small and medium farmers living in areas where
there is no access to the national electricity grid or the
electricity service is inefficient.
The biogas consumption of milk cooling machines, with load
capacities ranging from 300 liters to 500 liters, oscillates
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between 0.97 to 2.02 m3 per hour, with an average of 1.60 m3. Enero 2018. [Online]. Available:
From these numbers, it can be concluded that, based on these https://repositorio.cepal.org/bitstream/handle/11362/4
capacities, small-scale biodigesters4 are required in order to 3236/1/S1800075_es.pdf. [Accessed 24 Junio 2019].
run a milk cooling system fueled with biogas, which would [2] Guía Agropecuaria, "guíagronicaragua.com," Guía
have an organic waste demand of 150 kg to 300 kg of manure Agropecuaria, 2013. [Online]. Available:
per day5 [9]. http://guiagronicaragua.com/wp-
The use of open-compressors driven by biogas fueled engines content/uploads/2016/11/Una-mirada-alsector-.
has comparative advantages over electric compressors [Accessed 24 Junio 2019].
running on energy provided by the national electricity grid. [3] G. Bylund, The Dairy Processing Handbook, Lund:
The use of dual-type Otto engines (Gasoline/Biogas) reduces Tetra Pak Processing System AB, 1995.
the costs of electricity bills and mitigates the risks of [4] C. Bueso, G. Largaespada, E. Valle, P. Úbeda, B.
commercial electricity power cuts. The inclusion of a 12V Núñez and Á. Leiva, "Estudio Desarrollo y Validación
electrical system, with storage capacity and, powered by the del Enfriamiento de Leche a Partir de Biogás,"
same energy generated with the internal combustion engine Programa de Desarrollo del Mercado de Biogás en
provides total autonomy to the cooling system and Nicaragua, Managua, Nicaragua, 2018.
independence from the power coming from the national [5] C. Y and B. M, Termodinámica, México: McGRAW-
electricity grid. HILL/INTERAMERICANA EDITORES, S.A. DE
C.V., 2009.
Thermodynamic calculations initially performed, where it
[6] BITZER, "bitzer@bitzer.de//www.bitzer.de," BITZER
was established that the coolant volumetric displacement
Kuhlmaschinenbau GmbH, Abril 2010. [Online].
necessary for milk cooling is in the average of 1.968 m3/h,
Available:
were validated by the cooling equipment adaptation. It can
https://www.bitzer.de/shared_media/documentation/kp
be concluded that open-type compressors IY and IIY driven -510-3.pdf. [Accessed 6 Junio 2019].
by combustion engines of 9 HP and 13 HP respectively 6
[7] G. D, Tecnología del Automóvil, Barcelona:
fueled with biogas, are totally functional, and they can cool
REVERTÉ, 1980.
down the raw milk on times established by international
regulations. [8] K. Rolle, Termodinámica, Mexico: PEARSON
EDUCACIÓN, 2006.
The solution of moving the angle of advance of the crankshaft [9] J. Martí Herrero, Biodigestores Familiaries: Guía de
forward by 25° resulted in the improvement of two critical Diseño y Manual de Instalación, La Paz, Bolivia: GTZ,
indicators which was very important for a successful 2008.
implementation of cooling systems powered by engines
fueled with biogas. On the one hand, the solution reduced
power losses when the engine was fueled with biogas instead
of gasoline. On the other hand, the engine, when fueled with VIII. AUTHORS
biogas, increases its efficiency reducing fuel consumption by
15.7%. Alvaro Leiva, First Author
Mr. Álvaro Leiva holds a Bachelor´s Degree
The adaptation of a milk cooling system, covering the
in Industrial Engineering issued by the
modification of its manufacturer ́s condition permits to work National University of Engineering and a
with biogas as the main fuel option as it is profitable. Bachelor´s Degree in Educational
Financial data show positive numbers by the end of the Psychology issued by the National University of Nicaragua.
second year. The numbers increase from the savings Currently, he is the Coordinator of the Center for Research
originated from the substitution of either payments--the and Innovation with Alternative Energies (CIDTEA) of La
consumption of electricity through the national electricity Salle Technological University (ULSA), at Leon, Nicaragua.
grid or the procurement of gasoline at higher prices-- for the As CIDTEA ś Coordinator, he develops and coordinates the
use of biogas as fuel produced in the same farm. This data is implementation of Scientific Projects for ULSA, and/or with
very important for small and medium farmers located in the contribution of external entities, he also coordinates all
regions with or without access to services coming from the projects related to alternative energies. Since 2004, Mr.
national electricity grid. Leiva has had academic responsibilities. He started as
Coordinator of the Automotive Mechanics Department of La
VII. REFERENCES Salle Polytechnical Institute where he taught the course on
Automotive Mechanics until 2015. He has wide experience
[1] NACIONES UNIDAS, "Repositorio CEPAL.org," in education, mechanics, electricity, and automotive
División de Publicaciones y Servicios Web CEPAL, electronics and related subjects. Since 2016, he is a member
4 6
Fixed dome from 13 m3 to 30 m3, and/or tubular systems from 20m3 to Recommended for 300- and 500-liters tanks
50m3
5
This demand would be generated in a partially stabled cattle system of
15 to 30 cows respectively
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