BIOGAS Presentation
BIOGAS Presentation
The term BIOGAS is used for every type of fermentation/fouling gases which might emerge in nature where organic compounds gather and are cut off from oxygen supply, making an aerobe decomposition process no longer possible, - like at the bottom of lakes, swamps or even in the digestive system of ruminant animals. Synonyms for BIOGAS are such words as sewage gas, marsh gas, methane. Different micro organisms are metabolizing carbon from organic matter in oxygen-free environment (anaerobically). This process is known as decomposition or anoxic fermentation and follows the food chain.
BIOGAS is the end product of an aerobic decomposition process. This process can be divided into four distinct phases. During each process step, various micro organisms and a range of enzymes work symbiotically. BIOGAS itself is a gas mixture which mainly consists of Methane CH4, Carbon Dioxide CO2, and minor parts of Hydrogen Sulphide H2S, plus some other volatile Gases. Raw materials, like the following, can be used for biogas production: cattle manure, pig manure, chicken dung, slaughterhouse waste (blood, fat, entrails, and rumen content), plants waste, silage, rotten grain, waste water, fats, bio-waste, food industry waste, malt remnants, marc, distillery slop, bio ethanol plant slop, brewers grain (crushed malt remnants after filtration), sugar beet and fruit pulp, sugar beet tops, technical glycerine (after bio diesel production), fibre and other starch and treacle production, milk whey, flotation sludge, dewatered flotation sludge from municipal waste water treatment plants, algae. Most of the raw materials can be mixed with each other.
BIOGAS COMPONENTS Inflammable Methane CH4 Non-flammable Carbon Dioxide CO2 Hydrogen Sulphide H2S Hydrogen H2 Oxygen O2 Nitrogen N2 CHARACTERISTICS-BIOGAS Density Heating value Ignition temperature Ignition concentration/gas Scent/smell
50-70% 30-45% 0 - 1% 0 - 1% 0 - 1% 0 1%
1.2 kg/m 4-7.5 kWh/m 700 degrees C 6-12% rotten eggs/hydrogen sulphide
The higher the share of methane in BIOGAS the more energy-rich the gas will be. Not exploitable is carbon dioxide and water vapour. Problematic in BIOGAS is first of all hydrogen sulphide and ammonia which both have to be removed before the combustion process in order to protect the gas engines against these aggressive compounds. Good basic material for the technical production of BIOGAS is dung/liquid manure. The average dung production of livestock/cattle is approximately 1.5 m per month (depending on type of livestock, age of animal, feeding etc.). From the amount of liquid manure per day of on cattle we can win approx. 1.5 m BIOGAS the gas volume of 1 m equals approx. 0.65 litres if diesel or 0.66 m of natural gas. With the calorific value of BIOGAS (average heat rating!) of 6.5 kWh/m we are able to produce 2 kWh electrical energy. With addition of other organic compounds (co-substrates!) the exploitation of BIOGAS can be improved. Co-Substrates are: Renewable raw materials (corn, maize, grass, remnants from breweries, vineyards etc.) Agriculture waste material Waste from food production
Most BIOGAS plants work after a continuous flow process. The fermenter is daily fed with raw materials (silage!), while the same amount is being withdrawn from the fermenting vessel.
1. Silage analysis__________________________
State of the art analytical laboratories determine all relevant Parameters for an accurate assessment of silage quality. Dry matter content pH Crude nutrient analysis Energy content Fermentation acid spectrum NH3-N Trace and macro element analysis Assessment of storage stability Assessment of fermentation profiles
2. Fermenter analysis______________________
Sophisticated laboratory facilities analyse micronutrients using leading-edge procedures (iCAP spectrometry) even at the lowest concentrations. Dry matter content, organic dry matter content (oDM) pH Organic acids Ammonia nitrogen TOA/TAC ratio (total organic acids/total anorganic carbon) acid/alkalinity ratio, best under 4.0 Macro- and trace elements Calculation of the fermenter-specific requirement for essential micronutrients Production of tailor-made BC.PRO micronutrient mixtures
Methan CH4 (0-100 vol.%) Carbon Dioxide CO2 (0-100 vol.%) Hydrogen sulphide H2S (0-10, 0-30, 0-200, 0-500, 0-1500, 0-3000 or 0-5000 ppm) Oxygen O2 (0-25 vol.%) Hydrogen H2 (0-2000 or 0-5000 ppm, 0-20000, 0-50000 ppm) More gases and other concentrations on request Integration and supply of further sensors possible (e. g. pressure, temperature, flow, humidity, fill level, etc.)
GMC Biogas 08
Biogasanalysator from Bieler + Lang Gmbh
Thermal mass flow-meter in the biogas pipe upstream the block heat and power plant with gas engine. In order to control the fermentation process and allow for balancing, the gas quantity in larger plants is measured at different points: directly downstream the production site and upstream the induct side into the gas engine.
LINK:
http://www.abb.com/industries/ap/seitp410/c97a9398ad88a89ac125757b0063bd36.aspx
http://www05.abb.com/global/scot/scot211.nsf/veritydisplay/57264ec82b40b7bac125744100300156/$file/50_14-05-enrevd-04_2008.pdf
Practical study:
If the fermentation biology is out of balance what to do when things go wrong.
Despite all precautions, fermentation processes can go wrong. Serious problems are often due to a number of causes that are interlinked. Never just wait and hope that the fermenter will regain its balance again. You must identify the cause of the problem and develop a plan to rectify the situation and to prevent it in the future. In order to detect disruptions in the process at the earliest possible stage, we recommend that operators carry out regular fermenter analyses. This applies in particular to plants with high throughput rates or where a number of different substrates are processed. A deficiency of essential nutrients is not the only cause for impaired fermentation. There are other "typical" operating errors such as sudden changes in the fermenter temperature, excess nutrient supply upon substrate change or the fast feed of substrates with high fat or protein content.
Animal By-products
The inefficient treatment of slaughterhouse waste or improper use of products produced from it led to the pandemic occurrence of animal diseases throughout Europe. The EU has therefore introduced rigorous regulations on the collection, transport, methods and procedures of treatment, and further disposal of animal by-products, as well as the use of or trade in the products (Regulation (EC) No. 1774/2002). The Swiss Government also released a comparable regulation. The waste material is classified in three categories: Category 1 products bear increased risk for human and animal health (BSE, foot and mouth disease, etc.) and have to be incinerated. The Categories 2 (perished animals or animals slaughtered, but not intended for human consumption, milk and colostrums, manure as well as digestive tract content) and 3 materials (meat-containing wastes from the foodstuff industry, slaughterhouse waste of animals fit for human consumption, catering waste) are strongly recommended for biogas production after sanitising. The special requirements of slaughterhouse waste mean it is particularly well suited for large co-digestion plants.
Slaughterhouse waste: converting fatty waste into soap to improve biogas yield
The INRA* Laboratory for Environmental Biotechnology with the participation of the Energy-Environment Group of the FNEAP** and the SNIV***, has been carrying out experimental research aimed at managing fatty waste from cattle through the production of biogas. The research consists in applying thermo-chemical pre-treatment in order to process this waste and thus transform animal fats into soap which will improve the biogas yield during anaerobic digestion. Link:
http://www.international.inra.fr/partnerships/with_the_private_sector/live_from_the_labs/slaughterhouse_waste_con verting_fatty_waste_into_soap_to_improve_biogas_yield
Link: http://www.demetrion.com/?l=en
BIOGAS PLANTS
PLANT COMPONENTS
For a good blending and transportation within the plant system a variety of pumps, valves and mixing equipment has to be installed.
Link: http://www.eisele.de/english/start/start.htm
The Vielfrass infeed unit for solids is ideally suited for feeding solid dung, grass or maize silage and similar biomasses into a digester. Despite these high demands, the Vielfrass consumes very little power of its own. The screw conveyor and planetary gearing are particularly massive and robust. All parts subject to corrosion are made in V2A stainless steel. Intervall control ensures uniform, automated feed.
We designed the Paddelgigant especially for substrates with a high proportion of fibrous renewable resources. Four inclined paddles create a variety of flow directions. By this means the sustainable input materials and the manure in the digester are slowly mixed in a manner conducive to bacteria activity.
Fill level monitoring "at a glance" makes operating the plant easier. A focus test conducted by the German Agricultural Society (Deutsche Landwirtsgesellschaft, DLG) recently confirmed the excellent characteristics of Biolene. The principle of our biogas storage membrane is simple. Where maintenance is taking place or gas production fluctuates, the volume of stored gas constantly changes. In small gas storage vessels such fluctuations mean that biogas must be released and/or burnt unnecessarily; alternatively, CHPS utilisation is inefficient. With Biolene, all this is a different story. This flexible gas storage membrane from agriKomp is made from high-quality EPDM rubber. Placed over the fermentation residue vessel, this highly elastic cover captures and stores biogas as it forms.
Simply separate using the Quetschprofi rather than going on with costly mixing! The optimum press-out pressure of the separator for manure and fermented residue depends on the composition of the feedstock. Its infinitely adjustable pneumatic cylinder responds flexibly to varying levels of dry material and delivers reliably consistent separation.
Thanks to their robust technology, biogas systems made by agriKomp are operated using high contents of cheap feedstock like solid dung, grass and silage. The naturally high fibre contents in these substrates place great demands on both the technology and the biology. The raw fibre in the substrate is extremely difficult to "digest" for the methane bacteria in the digester. In the so-called "boiler" from agriKomp, the unprocessed contents of raw fibre are broken down in a thermal process so that they can be processed more easily by the bacteria.
AN ALLROUNDER
Corn Silage Sugar beets Grass Cutting
Organic Waste
Packed Food
Slaughterhouse Waste
www.mewa-recycling.com
MeWa Recycling
In planning your biogas plant we take all the parameters of your operation into account, together with your individual wishes. And if no existing modular or mobile biogas system concept matches your requirements, we will develop and manufacture a custom solution for. The combined heat and power unit is the heart of a biogas plant. Converting the biogas produced into electricity efficiently is a decisive factor for the viability of the plant. Seemingly slight differences in efficiency exert a major influence on the revenue that can be obtained. Additionally, biogas places special requirements on the CHP unit. For this reason we use only trusted technology from leading manufacturers developed specifically for this purpose.
Capstone Micro Turbines can cleanly burn waste gases to create renewable power and heat.
Capstone MicroTurbines are efficient and clean burning. The CR65 line of micro turbines meet the strict exhaust emissions requirements of the California Air Resources Board (CARB) for operation on landfill and digester gases, and were the first power generation systems to receive this CARB certification. The CR65 is also available with an integrated heat recovery module, which is ideal for applications that need both heat and power such as for anaerobic digesters. The CR200, CR600, CR800, and CR1000 will also be CARB certified for operation on these waste fuels, so you are sure to have low emissions for any project size.
Lipp builds tanks and containers: ingeniously simple and simply ingenious
The efficient on-site production allows for fast, inexpensive assembly of silos with a variable diameter of between 3 and 30 metres and a height of up to 40 metres, with optional filling and removal technology.
High quality and a long service life Excellent stability thanks to Lipp Dual-Seam System Free choice of RAL colours Expansion option Short construction time Construction without container boarding and scaffolding Type statics DIBT approval Broad assortment of peripheral accessories
A Lipp Dual-Seam System: the fastest, simplest way to flexibly build reliable containers and tanks.
Link: http://www.lipp-system.de/36-lipp_system.html
PRINCIPLE:
Renewable energy from waste, e.g. liquid manure, organic waste from household, trade and industry Economic operation of small biogas plants by patented technology > 100 cattle units, = 25 - 50 kW electrical power No mechanical moving parts and no electrical parts in the fermenter Thermo-Gas-Lift gently heats and stirs the fermenter through thermal convection and rising bubbles. Better utilisation of substrates and improved gas quality
BENEFITS:
Power production as green energy - special feed-in tariff. Generation of heat - substitution of fossil fuel and gas. Farm-scale recycling of nutrients in the digestate. Digestate with higher nutrient availability for plants and reduced odour nuisance compared to dung/manure. Revenues for treatment of organic wastes. CO2 emission certificate for the standardised biogas plant.
Build your biogas plant in 18 days Farm biogas plants for 100 cows ~ 20kW elk. CHP
prefabricated patent protected reactor ~220 m3 preinstalled, plug and start ~CHP 20kW elk. connect reactor with preinstalled CHP ready in 18 days produce your own electricity and heat for house & stable ideal for small farms and communities
Build your own reactor with prefabricated elements in 18 days. Connect the preinstalled CHP with your reactor. Now you are ready to produce heat and electricity (CHP). Methane (CH4) could also be used to power your truck /tractor. Minimum amount manure necessary: 2000 m3 (qm) per annum ~ manure of 100 cows. This produces about 150.000 kWh p.a. with a 20 kW elec. CHP (about 30kW term.). The patent protected reactor was developed by the University of Innsbruck in Austria.
According to your liquid manure amount and your individual needs we can offer following standardized fermenter sizes for 200, 300, 400, 500 and 600 m volume with the fitting cogeneration plants CHP of 30, 50,75, 100, 120, 150, 220, 360 kW electrical power output. Should one fermenter unit not being enough or did your waste production increase after your first instalment just build another one! Does it sound un-economical to you? No it is absolutely not! If you consider possible repairs or mal functions in a large biogas unit considering you might have to empty the tanks and shut down the whole plant for days (the mixing equipment in larger units do have the tendency to break down every now and than due to daily operation in a very aggressive environment) you are far better of with 2 or even 4 smaller units when you can continue energy production with the working units. The same situation goes if you should have a shortage in substrates also here it is easy to limit your production without having to close the whole plant.
TARGET GROUPS:
Agricultural farms, winery, poultry pigg farms, horse breeder stables Waste management companies respectively communes waste water sludge Trade and industrial firms, food production
Also in the production we do have carbon dioxide as a by-product of fermentation, more so when burning methane gases to produce electrical energy. The idea now was, - how can we use these gases in a productive manner?
The algae industry today is moving towards multiple applications including nutraceuticals, cosmetics, animal feed, carbon capture & recycle and waste water treatment, while research into cost effective bio ethanol, bio diesel and other bio energy production continues behind the scene. We have planed and completed our business model which reflects the shift from the algae-bio fuel hype to a sustainable business enabling satisfying returns on investment.
African Students get their education at the Algae Bio Reactor Plant from the German Power Supplier RWE LINK: http://www.rwe.com/web/cms/en/2652/rwe/innovations/power-generation/clean-coal/algae-project/
FURTHER SYNERGIES
Absorption heat cooling machines will use the aggregate heat from the gas engine for cooling. (here: BROAD Outdoor Package Chiller) Link: http://www.gasklima.de/broad.0.html
Absorption cooling
The aggregate heat from the cogeneration unit can be used in a refrigeration machine using ammoniac and water as refrigerant temperatures down to -70 degrees are possible.
Additional Information
From the Biogas Plant Producer BIO CONSTRUCT: http://www.bioconstruct.com/ HOW TO BUILD A BIOGAS PLANT: http://www.youtube.com/watch?v=mCebM7a5XBQ&NR=1 From the Biogas Producer ENVITEC: http://www.envitec-biogas.de/ VIRTUAL TOUR THROUGH A BIOGAS PLANT: http://www.youtube.com/watch?v=QPeGpwnXkZk&feature=related
Anaerobic bacteria
Micro organisms that live and multiply in an environment containing no free or dissolved oxygen.
Anaerobic decomposition
Decomposition of organic substances caused by anaerobic bacteria, partially with release of biogas.
Base substrate
Fertiliser to be used for fermentation purposes.
Biogas
Product of anaerobic biological decomposition or organic matter. Contains approx. 45-70 % methane, 30-55 % carbon dioxide, small quantities of nitrogen, hydrogen sulphide and other trace gases.
Biogas plant
Plant for the production, storage and utilisation of biogas, including all necessary equipment and fixtures . Biogas is thereby produced by means of fermentation of organic substances.
Buffer capacity
The buffer capacity is the quantity of a strong acid required to adjust the pH to a predefined value (e.g. 4.4).
Carbon dioxide
Colourless, non-flammable, non-toxic gas with a slightly acidic smell, produced together with water when an organic compound is combusted.
Condensate
Biogas produced in the fermenter is saturated with water vapour and must be dried before it is used in the combined heat and power plant. This is done by installing a sufficiently dimensioned earth line in a condensate trap, or by drying the biogas.
Co-substrate
Organic material that is not a fertiliser and is destined for fermentation.
C/N ratio
Ratio between carbon and nitrogen in a substrate. The C/N ratio of the substrate to be fermented is important for a good fermentation process (ideal ratio: 13/30). The C/N ratio in the fermented substrate can be used to determine the availability of nitrogen for fertilisation (ideal: 13).
Decomposition
The decomposition of organic compounds consisting of many atoms into smaller molecules by means of biotic or non-biotic processes. Biotic decomposition is caused by biological processes (e.g. by enzymes or micro organisms). Non-biotic decomposition is caused by chemical reactions (e.g. slow oxidation, combustion, conversion) or physical influences (e.g. UV radiation).
Degradability
Property of a substance that can be decomposed by biochemical, chemical or physical reactions. The end products of the reactions are either other compounds (metabolites) or in the case of complete mineralization CO2, H2O, NH3.
Desulphurisation
Biological or chemical process for the removal of sulphur from biogas.
Dwell time
Average retention time of the substrate in the fermenter.
Emission
Release of fumes, gases, dust, affluent or odours into the environment. Emissions also include noise, vibration, light and heat radiation.
Fat separator
Device for the separation of non-emulsified organic oils and fats, installed for example in wastewater systems of restaurants, commercial kitchens, meat factories, meat and fish processing plants, margarine factories and oil mills (see DIN 4040).
Fermentation residue
Material left over in the fermenter after biogas production, biogas production by-product.
Gas dome
Structure placed on fermentation vessel in which biogas is collected for further use.
Gas storage
Room or area where the gas tank is installed.
Gas tank
Gastight vessel or foil bag in which biogas is temporarily stored.
Hygienisation
Process step for reduction and/or elimination of disease agents and/or phytopathogens. BioAbfV or EC Hygiene regulations give information about the process.
K value
Heat transfer coefficient, also known as K value, is a measure for thermal insulation properties. It corresponds to the heat that is conducted through a surface of one square meter of a material at a temperature difference of one degree Celsius. The smaller the K value, the lower the heat loss.
Methane (CH4)
Colourless, odourless and non-toxic gas. Releases carbon dioxide and water when combusted. Methane is one of the key greenhouse gases and is contained in biogas, natural gas, sewer gas and landfill gas.
Nitrogen oxide
The gases nitrogen monoxide (NO) and nitrogen dioxide (NO2) are also referred to as NOx (nitrogen oxides). They occur in all combustion processes (especially at high temperatures) when the nitrogen in the air reacts with the oxygen, or where compounds containing nitrogen are oxidised.
Preparation
Preliminary treatment of a material (e.g. chopping, removal of unwanted substances, homogenisation, etc.).
Rate of degradation
The rate of the biological or chemical degradation of organic compounds,
Solid transfer
Method for the transfer of non-pump able substrates or substrate mixtures to the fermenter.
Sulphur dioxide
Colourless gas, with a pungent smell, produced by combusting sulphur or roasting sulphides. The corresponding aqueous solution is known as sulphurous acid.
Substrate
Organic bio-degradable material collected for the purpose of fermentation for the production of biogas.
Throughput
Quantity of material feed to and processed in a plant per time unit.
VOA/TAC
VOA/TAC is the ratio of volatile organic acids to total anorganic carbon (carbonate buffer capacity).
Volume load
Organic content of the material brought into the fermenter relative to the usable fermenter capacity per time unit. Expressed in kg ODS/m*d.
Sometimes Biogas even creates Wonders!!! Wonders!!! Maybe they inhaled it!?