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Innovative System for Animal Waste Utilization Using Closed-Loop Material and Energy Cycles and Bioenergy: A Case Study

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  • Zygmunt Kowalski

    (Mineral and Energy Economy Research Institute, Polish Academy of Sciences, Wybickiego 7A, 31-261 Kraków, Poland)

  • Agnieszka Makara

    (Cracow University of Technology, Faculty of Chemical Engineering and Technology, Warszawska 24, 31-155 Kraków, Poland)

Abstract

This study proposes an innovative model for animal waste utilization in the largest Polish meat utilization plant, which assumes an integrated system that processes one part of the meat waste by anaerobic digestion and the second part into meat and bone meal via the hydrothermal method. The solution is based on implementing the concept of industrial symbiosis, using a purposefully directed flow of materials, waste, and energy to create a closed recycling cycle. This study analyzes the key strategic, organizational, and technical circular economy activities that enable the transformation of waste into valuable materials and energy, thanks to the use of closed-loop materials and energy cycles. It estimates the integrated system’s investment costs and economic and environmental outcomes. The presented method allows for biogas production from the bio-fermentation of 160,000 t/y of animal waste; this would more than cover the heat requirements for obtaining 110,000 t/y of meat and bone meal using the hydrothermal method.

Suggested Citation

  • Zygmunt Kowalski & Agnieszka Makara, 2025. "Innovative System for Animal Waste Utilization Using Closed-Loop Material and Energy Cycles and Bioenergy: A Case Study," Energies, MDPI, vol. 18(10), pages 1-18, May.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:10:p:2579-:d:1657432
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    References listed on IDEAS

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    1. Kythreotou, Nicoletta & Florides, Georgios & Tassou, Savvas A., 2014. "A review of simple to scientific models for anaerobic digestion," Renewable Energy, Elsevier, vol. 71(C), pages 701-714.
    2. Cieślik, Marta & Dach, Jacek & Lewicki, Andrzej & Smurzyńska, Anna & Janczak, Damian & Pawlicka-Kaczorowska, Joanna & Boniecki, Piotr & Cyplik, Paweł & Czekała, Wojciech & Jóźwiakowski, Krzysztof, 2016. "Methane fermentation of the maize straw silage under meso- and thermophilic conditions," Energy, Elsevier, vol. 115(P2), pages 1495-1502.
    3. Zygmunt Kowalski & Agnieszka Makara, 2022. "Sustainable Systems for the Production of District Heating Using Meat-Bone Meal as Biofuel: A Polish Case Study," Energies, MDPI, vol. 15(10), pages 1-15, May.
    4. Gulnar Gadirli & Agnieszka A. Pilarska & Jacek Dach & Krzysztof Pilarski & Alicja Kolasa-Więcek & Klaudia Borowiak, 2024. "Fundamentals, Operation and Global Prospects for the Development of Biogas Plants—A Review," Energies, MDPI, vol. 17(3), pages 1-26, January.
    5. Wang, Shunli & Hawkins, Gary L. & Kiepper, Brian H. & Das, Keshav C., 2018. "Treatment of slaughterhouse blood waste using pilot scale two-stage anaerobic digesters for biogas production," Renewable Energy, Elsevier, vol. 126(C), pages 552-562.
    6. João Pinto & Rui Boavida-Dias & Henrique A. Matos & João Azevedo, 2022. "Analysis of the Food Loss and Waste Valorisation of Animal By-Products from the Retail Sector," Sustainability, MDPI, vol. 14(5), pages 1-27, February.
    7. Zygmunt Kowalski & Joanna Kulczycka & Agnieszka Makara & Giovanni Mondello & Roberta Salomone, 2023. "Industrial Symbiosis for Sustainable Management of Meat Waste: The Case of Śmiłowo Eco-Industrial Park, Poland," IJERPH, MDPI, vol. 20(6), pages 1-22, March.
    8. Hakawati, Rawan & Smyth, Beatrice M. & McCullough, Geoffrey & De Rosa, Fabio & Rooney, David, 2017. "What is the most energy efficient route for biogas utilization: Heat, electricity or transport?," Applied Energy, Elsevier, vol. 206(C), pages 1076-1087.
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