Hydrogen and Methane Production by Single- and Two-Stage Anaerobic Digestion of Second Cheese Whey: Economic Performances and GHG Emissions Evaluation

This study aimed at evaluating the economic performances of and carbon footprint associated with innovative systems for the energetic valorization of second cheese whey (SCW), a by-product of whey cheese manufacture, through anaerobic digestion processes. Three systems were modeled: a conventional single-stage anaerobic digester (FAD), located at about 50 km from the dairy factory; an on-site conventional single-stage anaerobic digester (CAD), located at the dairy industry; and an on-site two-stage anaerobic digester (TAD). The TAD technology enables the simultaneous production of hydrogen and methane on site. The biogases produced were combusted in combined heat and power plants (CHP), but only the onsite systems provided process heat to the dairy factory. In the specific conditions assumed, TAD configuration exhibited a higher energy output, which led to a GHG emission reduction of about 60% compared to FAD, mostly thanks to the additional hydrogen (H2) production and the improved engine performances. A detailed cost analysis confirmed the results of the environmental analysis, pointing to the TAD solution as the most economically viable, with a payback period of 9 years, while the CAD had a payback time of 12 years. The results here presented aim at providing the dairy industry with a robust economic analysis on the opportunity of building an innovative system for SCW valorization, as well as providing policymakers with environmental reliable data to support the promotion of this technology.