The True Challenges & Risks of Biogas and its Utilization Options in Thailand 1
Technologies B iogas Production Plants L andfill Gas Recovery B iogas Engine Generators B iogas Purification B iomass Fired Heat and Power Plants M unicipal Solid Waste Treatment Plants W aste Heat Recovery Systems 2
Typical Applications for Biogas in Thailand Farm Waste Agri-Industrial Waste (Starch, Palm Oil, Sugar,….) Landfill Gas Ethanol WW from Molasses and cassava Napier Grass (NEW and Special) Seafood Industry Tropical Fruit Processing Slaughterhouse Waste OFMSW General Food and Beverage Industry 3
Biogas Production Technology How it works Biogas Treated Wastewater Wastewater Inlet 4
Biomethanation Reactors (1) • Technical solutions do exist for all organic substrates to produce Biogas. • Many reactor types are available, mesophilic or thermophilic. • High tech and high performance solutions. • Low tech and low performance solutions. 5
Biomethanation Reactors • Various pre- and post- treatments are available and must be carefully engineered and selected. 6
Different Reactors (1) Medium/High Loading Low/Medium Loading Rate: Rate beet sugar, starch, fermentation (alcohol, brewery, soft drinks. baker’s yeast, citric acid), Juices, fruit & veg. fish and meat processing, processing, potato & slaughterhouse, corn processing, rendering, dairy industry. slaughterhouse, rendering, cheese processing. High Loading Rate - Tower
Different Reactors (2) High FOG: Oil & Toxicity Fermentation Proof: Fish & Meat, Petrochemical Slaughter- Applications, houses, Rendering, Cheese Processing. Alternative Sludge & Reactor: Slurries: Covered Molasses lagoon, distilleries Molasses Sludges, distilleries, pulps Pulp & Paper Industry, and many more applications where space is 8 available
Biogas Utilization Material for reactor tanks: new options for Thailand round bolted steel tanks, pre coated inside/outside 9
Biogas Utilization Inground or covered lagoon reactors are very common here in Thailand. Where space does not matter, where feedstocks are unstable and undefined! or even for post treatment, probably a realistic solution. 10
Biogas Production 11
Examples of Biogas Projects in Thailand 100 % bunker oil replacement + 2.6 MW electricity generation 100 % bunker oil replacement. 12
Selected References 13
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Biogas Utilization • The biogas can be utilized in many ways depending on the thermal or electricity energy requirements of your factory such as fuel replacement for boiler, electricity generation etc. Thanks to Thailand‟s “adder” system you are motivated to sell to the grid. You might also want to produce CBG (compressed biogas) for use as vehicle fuel 17
Biogas Production and Methane Gas Estimation • The estimation of the biogas production rate and methane gas content is the first step in the biogas utilization plan. • The major factors are biodegradable COD load and flow rate of the wastewater. • These factors are related to the raw material, the capacity of the plant, and the production process. 18
Wastewater Treatment Concerns (2) • How do I design the size of the plant, considering unstable feedstock supply patterns? • Do I go for maximum and invest in a plant which is then for certain periods too big and underutilized? • Or do I go for small and bypass the substrate/water for too long periods? 19
Wastewater Treatment Concerns (3) • How do I get my wastewater or solids to the reactor? • What space do I need? • Did I consider also biogas treatment for its intended purpose, i.e. power generation / boiler? • Do I need scrubbing (H2S..), drying? • How far do I have to transport the gas? 20
Investment and Financial Concern (1) • How do I optimize my revenue from the biogas plant? • Do I give preference to the power generators? The remaining gas to the boiler? Do I sell my power to the grid? • Do I replace other fossil fuels such as bunker oil? Where is the break-even? 21
Investment and Financial Concern (2) • Have I explored all financial initiatives available to support the implementation of the project? • Is my project generating carbon credits? Is it worth to follow all the CDM procedures? • Shall I invest myself or look for BOO/BOT partners? 22
Possibilities of Biogas Utilization Oil/ coal replacement Electricity generation Biogas Compressed Biogas
Consideration about the Biogas • Still: Biogas you do not buy thru a pipeline or from a tank or storage „on call‟ like other fuels but is the result of a biological process, which may bear unpredictable issues. The dependence to biogas must be well considered in terms of down stream processes, not only from smooth process flow but also commercial considerations must be applied! • …and above all: SAFETY! 24 24
Oil/ coal replacement Boilers Dual fuel burner systems 25
Electricity Generation CHP Plant Biogas blower Biogas scrubber Biogas drier 26
Biogas Cleaning (1) • Only methane in the biogas is a source of energy. • Some other compositions are not utilized for the energy production such as carbon dioxide, oxygen, hydrogen sulfide gas, small particle (dust), and moisture. • Biogas cleaning may be required. • Hydrogen sulfide gas (H2S) or moisture can damage the biogas utilizing equipment. 27
H2S Scrubbers • Biogas contains H 2 S, a very corrosive gas which is unwanted at the down stream equipment such as engines, biogas purifiers but also in (SO x ) emmissions. • Bioscrubbers are here the optimal solution. 28
Biogas Cleaning (2) Hydrogen Sulfide gas (H 2 S) • Corrosive to metal part of the equipment. • H 2 S gas production based on the raw materials: – Ethanol from molasses: commonly 20-30,000 ppm – Cassava Starch: 3,000 ppm • The maximum limit of H 2 S: – Electricity generator:200 ppm. (or lower) – Burner and boiler: 2,000 – 5,000 ppm. – (better none or low, also for emission reasons) 29
Biogas Cleaning Techniques • Scrubbing/Sweetening : H 2 S gas and dust removal. • Dryer/Demister : H 2 O content removal. 30
BioGasclean Asia Biological H 2 S removal Peter Thygesen, BioGasclean Asia Renewable Energy Asia, Bitec Bangkok, June, 2013
BioGasclean A/S Denmark, Head office BioGasclean Asia Co.,Ltd, Thailand • Leaders in biological removal of H 2 S from biogas. • Have worked on most known substrates and engines. • Have installations in about 30 countries. • Have more than 110 installations with an installed generating capacity of over 280 MW
Basic Value-chain on a Biogas plant 3. 1. 2. Energy & Power Biogas Gas Treatment: generation Generation: H2S removal • Gas Engine Conversion of Drying Boiler COD to Biogas Pressure adjustment Each step is equally important and need to operate with high reliability to create revenue on the plant
Key points in reliable H 2 S removal • Proper knowhow in design and dimensioning • Materials in the right quality for high corrosive environment. • Integration of the system on the biogas plant • Advances Process control • Safety considerations • Operation and Maintenance • After Sales Service
P/V valve Bio scrubber Tan k principle Spray system • Air injection • Effluent water adding • Pre-treatment(MUW) PTU Gas outlet Effluent MUW tanks Storage Gas inlet tank O 2 Air High Blower Circulating level Low pump level MgSO 4, MgSO 4, Effluent SO 4 2 CaSO 4 CaSO 4 - Pump Gutter Auto Drain
BiogasCleaner FRP tank Thailand Capacity: 700 Nm 3 /h. 3.000 ppm H 2 S => 100 ppm Cassava WWTP
BiogasCleaner 3 FRP tanks Denmark, Design Capacity: 3,600m 3 /h – 3,000ppm
PTU in FRP housing
BiogasCleaner built on-site Thailand Design Capacity: 1.670 Nm 3 /h, 30.000 ppm H 2 S => 100 ppm Sugar cane molasses ethanol WWTP
Cost for H 2 S removal Example1: 3,000 ppm H 2 S (Cassava and POME) • Treatment cost per 1,000 m 3 = 70 THB • Cost per MW electrical produced = 34 THB Example 2: 20,000 ppm H 2 S (Molasses based Ethanol) • Treatment cost per 1,000 m 3 = 465 THB • Cost per MW electrical produced = 225 THB. • Average Selling price for 1 MW in Thailand = 3,100 THB Budget conditions: Plant life 15 years; 8,000 h operation/y, Maintenance & QSR cleaning, 3 MW installation with 1,600 m 3 /h capacity.
References No. Country No. Power MW 1 Thailand 35 110 2 Denmark 10 25 3 Malaysia 8 20 4 U.S.A. 8 20 5 Guatemala 4 6 6 India 6 9 7 Indonesia 6 11 8 Canada 5 18 9 Turkey 3 5 10 Argentina/China/Mexico/Morocco/Pakistan/ 14 27 to Israel/ South Africa (2 INSTALLATIONS EACH) 16 17 Australia/Brazil/Colombia/Cambodia/Finland 13 34 to Italy/Lithuania/Netherland/New Zealand 29 Poland/UK/Vietnam/Laos (1 INSTALLATION EACH) TOTAL 112 285
Thank You Asia www.biogasclean.com
Biogas upgrading technology 43
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