Nestle develops environmentally sustainable manufacturing and reduces its carbon footprint
Nestlé’s on-site anaerobic digestion plant is supplying about eight percent of its factory’s electricity demand and has eliminated its solid waste handling costs one year after commissioning.
The on-site bio-energy plant was designed and built by Clearfleau for Nestlé’s Fawdon confectionery factory, near Newcastle, UK. In addition to the financial benefits, the plant is helping Nestlé reduce its carbon footprint and develop environmentally sustainable manufacturing at Fawdon.
The plant converts 200,000 liters per day of feedstock into renewable energy. This feedstock includes wastewater from the site and 1,200 tonnes of residual byproducts and ingredients per year.
The biogas produced is fueling a combined heat and power engine, which produces 200kW of electricity, used in the confectionery production process. This is about eight percent of the factory’s power requirements, cutting the annual electricity bill by about £100,000 per year.
In addition, the site has registered for the UK Feed in Tariff, and will receive annual payments of about £250,000 per year.
Previously, production residues from Fawdon were discharged to sewer or fed to pigs in the locality. Following the installation of the AD plant, all biodegradable production residues are now converted into renewable energy on the factory site.
Ultium Cells LLC/Li-Cycle: Sustainable Battery Manufacturing
Ultium Cells LLC - a joint venture between General Motors and LG Energy Solutions - has announced its latest collaboration with Li-Cycle. Joining forces the two have set ambitions to expand recycling in North America, recycling up to 100% of the scrap materials in battery cell manufacturing
What is Ultium Cells LLC?
Announcing their partnership in December 2019, General Motors (GM) and LG Energy Solutions established Ultium Cells LLC with a mission to “ensure excellence of Battery Cell Manufacturing through implementation of best practices from each company to contribute [to the] expansion of a Zero Emission propulsion on a global scale.”
Who is Li-Cycle?
Founded in 2016, Li-Cycle leverages innovative solutions to address emerging and urgent challenges around the world.
As the use of Lithium-ion rechargeable batteries in automotive, industrial energy storage, and consumer electronic applications rises, Li-Cycle believes that “the world needs improved technology and supply chain innovations to better recycle these batteries, while also meeting the rapidly growing demand for critical and scarce battery-grade materials.”
Why are Ultium Cells LLC and Li-Cycle join forces?
By joining forces to expand the recycling of scrap materials in battery cell manufacturing in North America, the new recycling process will allow Ultium Cells LLC to recycle cobalt, nickel, lithium, graphite, copper, manganese and aluminum.
“95% of these materials can be used in the production of new batteries or for adjacent industries,” says GM, who explains that the new hydrometallurgical process emits 30% less greenhouse gases (GHGs) than traditional processes, minimising the environmental impact. Use of this process will begin later in the year (2021).
"Our combined efforts with Ultium Cells will be instrumental in redirecting battery manufacturing scrap from landfills and returning a substantial amount of valuable battery-grade materials back into the battery supply chain. This partnership is a critical step forward in advancing our proven lithium-ion resource recovery technology as a more sustainable alternative to mining, " said Ajay Kochhar, President, CEO and co-founder of Li-Cycle.
"GM's zero-waste initiative aims to divert more than 90% of its manufacturing waste from landfills and incineration globally by 2025. Now, we're going to work closely with Ultium Cells and Li-Cycle to help the industry get even better use out of the materials,” added Ken Morris, Vice President of Electric and Autonomous Vehicles, GM.
Since 2013, GM has recycled or reused 100% of the battery packs it has received from customers, with most current GM EVs repaired with refurbished packs.
"We strive to make more with less waste and energy expended. This is a crucial step in improving the sustainability of our components and manufacturing processes,” concluded Thomas Gallagher, Chief Operating Officer, Ultium Cells LLC.