FERNBROOK BIO’S PERFORMANCE IMPROVEMENT
Fernbrook Bio is a 1.5 MWe food waste AD facility in Northamptonshire. The plant was built in 2010 and expanded in 2012. The plant had struggled to achieve consistent performance from merchant feedstock for some months. Read on to understand how ONM helped to deliver greater plant stability and control – and improved performance.
Background
Whites Generation Ltd (WGL) bought Fernbrook Bio in 2016. In 2017, one of the plant digesters suffered an over-pressure event; and in 2019, there was a biological issue linked to feedstock. As a consequence, the performance of the plant had been variable ever since. WGL had invested significantly to increase the front-end processing capability and but then were in need of assistance in delivering consistent performance.
In March 2020, WGL asked ONM to take over the operational management of the plant, with a clear objective to improve the level and consistency of performance.
Engaging ONM
ONM were already familiar with the site. Ricky had been providing COTC cover for 18 months. Kyrone came to the site in March 2020 to meet with WGL’s chairman, James Astor. After finalising the details of the assignment, ONM were initially appointed on a 6-month contract to manage all aspects of the plant’s performance; H&S, environmental compliance, operations, and maintenance. ONM also introduced James to a candidate for the vacant position of site manager. The candidate was awarded the job and started in the role on the same day that ONM began their assignment.
On the back of the strong progress made to date, we are finalising a 12-month follow-on contract.
The investigation
Kyrone and Ricky started this assignment by conducting an in-depth audit of the site and its performance, leveraging the knowledge and experience of the team on the ground.
Analysing the site’s recent and historic operational data, they identified a number of areas that they felt required priority attention; and a longer list of actions that they felt would help to stabilise the plant’s long term performance.
The solution
Having completed the initial audit, ONM then started systematically working through the issues that they had identified with the on-site team. They took a rigorous approach to looking behind the outward symptom of a problem in order to identify the underlying issue causing it. In this way, the solutions that they put in place gradually increase the reliability of the plants on which they work.
A number of issues were down to equipment which had reached the end of its economic life. ONM made capex proposals to the WGL board. The board, in turn, have supported ONM’s work by providing the additional investment required.
The result
Four months into the assignment the plant is now delivering UK top quartile power generating performance.
The physical control of the plant is easier and tighter, and some unreliable equipment has been replaced.
The biological health of the digesters is significantly improved, and much more consistent.
The plant is fortunate to have Whites Recycling Ltd (WRL – an organics waste management company) as a partner, and WRL has been able to maintain feedstock supply through the Covid lockdown period when many food waste plants have suffered from reduced volumes.
As a consequence of the constant supply of food waste, and ONM’s much improved biological and operational control of the plant, electricity generation is currently at over 90% of the plant’s total capacity. This is a very significant improvement on the average performance over the previous 12 months, which has delighted WGL.
However, the work on an AD plant is never over! As well as now ensuring that the plant’s recent performance is sustained, ONM has been asked by WGL to review and improve the preventative maintenance process and spares strategy for the site.
WGL’s thoughts on ONM
“Kyrone and Ricky have done a terrific job in a short period of time. They have worked with the hardworking and talented team at Fernbrook to deliver real improvements quickly. They have brought detailed technical understanding and excellent problem-solving skills to bear on a range of issues that they have identified, and then systematically addressed.
I particularly appreciate their straight-talking approach, willingness to tackle difficult matters for the benefit of our long-term performance, and their strong focus on health, safety, and compliance. I wouldn’t hesitate to recommend them to others.”
James Astor, Chariman.
Whites Generation Ltd.
Our thoughts on the Fernbrook Bio project
“AD is a complex biological process, in need of sharp accuracy in process monitoring and control. By focusing on the steps needed to improve the monitoring and control at Fernbrook, we’ve been able to increase the stability and output of the plant.
Extending the contract for another 12 months gives us the time needed to address some other longer term projects, such as equipment life-cycles and supporting preventative maintenance procedures.”
Ricky Malin
Director
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