By Brian Kish and David Buck

Study of the Utilization of Bio-Gas (Methane) for the Coors Brewing

Company

IntroductionIntroduction

The Coors Bottling Plant has been The Coors Bottling Plant has been operating in Elkton, VA since 1987operating in Elkton, VA since 1987

Coors products are brought to the facility Coors products are brought to the facility by railcarsby railcars

Then they are blended, finished and Then they are blended, finished and packagedpackaged

The plant is located between the Blue The plant is located between the Blue Ridge Mountains and the South Fork of Ridge Mountains and the South Fork of the Shenandoah Riverthe Shenandoah River

The plant is designated Class I pristine The plant is designated Class I pristine for Environmental Permitting Conditionsfor Environmental Permitting Conditions

IntroductionIntroduction

Arial picture of the Virginia Facility of the Coors Brewing Arial picture of the Virginia Facility of the Coors Brewing Company, Shenandoah Bottling Plant. Company, Shenandoah Bottling Plant.

Expansion at the Coors PlantExpansion at the Coors Plant

Due to the increase in demand for their Due to the increase in demand for their product Coors is adding another bottle product Coors is adding another bottle and another can line to their plant in and another can line to their plant in Elkton, VAElkton, VA

Competitive Overview of 2000 Increase in Volume of Coors,

Miller, and AB

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Expansion at the Coors PlantExpansion at the Coors Plant

Expansion will also include upgrades to Expansion will also include upgrades to the wastewater treatment plant.the wastewater treatment plant.

Such as a Such as a Biogas BoilerBiogas Boiler Bulk Volume FermenterBulk Volume Fermenter Engine Driven Induction GeneratorEngine Driven Induction Generator Activated Sludge BasinActivated Sludge Basin Chlorine Contact TankChlorine Contact Tank

Wastewater Treatment Wastewater Treatment PlantPlant

The Bulk Volume FermenterThe Bulk Volume Fermenter

Needs to run at a minimum temperature Needs to run at a minimum temperature of 31 of 31 ooC for maximum efficiency.C for maximum efficiency.

In the winter the BVF drops below 31 In the winter the BVF drops below 31 ooC C resulting in lower treatment capacity.resulting in lower treatment capacity.

Produces methane gas burned as waste.Produces methane gas burned as waste. Previous EPA regulations had prevented Previous EPA regulations had prevented

Coors from using the excess methane for Coors from using the excess methane for energy.energy.

The Biogas BoilerThe Biogas Boiler

On August 15, 2000, Coors Brewing On August 15, 2000, Coors Brewing Company received and amendment to their Company received and amendment to their previous permit allowing the installation of previous permit allowing the installation of a biogas boiler.a biogas boiler.

The biogas boiler was specifically The biogas boiler was specifically approved to burn excess methane gas approved to burn excess methane gas produced by the anaerobic bacteria in the produced by the anaerobic bacteria in the BVF.BVF.

Used to maintain the temperature of the Used to maintain the temperature of the BVF at 31BVF at 31

oo C in winter months C in winter months A 10 A 10 o o C drop in temperature will result in C drop in temperature will result in

a 30-50% reduction in efficiency and a 30-50% reduction in efficiency and treatment capacity.treatment capacity.

The Biogas BoilerThe Biogas Boiler

Installation of an Induction Installation of an Induction GeneratorGenerator

The remaining 3.66 million Btu/hr of The remaining 3.66 million Btu/hr of surplus methane not used by the biogas surplus methane not used by the biogas boiler will be available to one or more boiler will be available to one or more induction generators.induction generators.

The generator will be used to provide The generator will be used to provide electricity for the waste water treatment electricity for the waste water treatment plant.plant.

Induction GeneratorInduction Generator

Regulation Involved in the Regulation Involved in the Installation of the Induction Installation of the Induction

GeneratorGenerator Determining if the induction generator Determining if the induction generator

will require a permit.will require a permit. Size of the generatorSize of the generator Fuel typeFuel type Emissions & emission levelsEmissions & emission levels

National Ambient Air Quality Standards (NAAQS)National Ambient Air Quality Standards (NAAQS)

  

 

 

Emission Rate Exemption Levels

Carbon monoxide 100 tons per year

Nitrogen dioxide 10 tons per year

Sulfur dioxide 10 tons per year

Particulate matter (PM10) 10 tons per year

Volatile organic compounds

10 tons per year

Lead 0.6 tons per year

Determining Emissions Determining Emissions Levels from Stack TestsLevels from Stack Tests

Stack tests were conducted by Jasper Stack tests were conducted by Jasper Tech Systems for the following Tech Systems for the following HydrocarbonsHydrocarbons Carbon Monoxide COCarbon Monoxide CO Carbon Dioxide COCarbon Dioxide CO22

Oxygen OOxygen O22

Nitrogen Oxides NONitrogen Oxides NOxx

Determining Emissions Determining Emissions Levels from Stack TestsLevels from Stack Tests

The Pollutants tested in the emissions The Pollutants tested in the emissions test were given in percent by volume and test were given in percent by volume and part per million (ppm) by volume.part per million (ppm) by volume.

The total exhaust of each pollutant by The total exhaust of each pollutant by volume had to be calculated in order to volume had to be calculated in order to determine the total amount of emissions determine the total amount of emissions in tons per year.in tons per year.

This was then multiplied by the density This was then multiplied by the density to get the total emissions per year by to get the total emissions per year by weightweight

A single engine had an exhaust rate of A single engine had an exhaust rate of 400 ft 400 ft33/min./min.

Determining Total Engine Determining Total Engine Exhaust Per Year from the Exhaust Per Year from the

Emissions TestEmissions Test(example calculation)(example calculation)

Total emissions of pollutant per year by Total emissions of pollutant per year by volumevolume

= (400 ft= (400 ft33/min) (0.1025)(60 min/hr)/min) (0.1025)(60 min/hr)

(8760 hrs/yr)(8760 hrs/yr) = 2.155 X 10 = 2.155 X 10 77 ft ft33/yr/yr

Note: 0.1025 represents the fraction of Note: 0.1025 represents the fraction of COCO22 by volume. by volume.

Density = Density = =144 P/R=144 P/R 144 = the number of square inches in a square foot144 = the number of square inches in a square foot R= the Universal Gas Constant =1544/MWR= the Universal Gas Constant =1544/MW

=1544/44 = 35.09=1544/44 = 35.09 P = pressure =14.7 psiP = pressure =14.7 psi T = temperature in Rankine = 960 T = temperature in Rankine = 960 ooRR R = 1544/MW R = 1544/MW

= 1544/44 = 35.09= 1544/44 = 35.09 = (144 X 14.7)/(35.09 X 960)= (144 X 14.7)/(35.09 X 960)

= 0.0628 lbs/ft= 0.0628 lbs/ft33

Total emissions of pollutant per year by Total emissions of pollutant per year by weightweight

= (0.0628 lls/ft= (0.0628 lls/ft33)(2.155 x 10)(2.155 x 1077 ft ft33/yr)/yr) = 1.35 x 10= 1.35 x 1066 lbs/yr lbs/yr = 677.684 tons/yr= 677.684 tons/yr

Determining Total Emissions Exhaust Determining Total Emissions Exhaust from EPA Datafrom EPA Data

Example Calculation using Sulfur Dioxide Example Calculation using Sulfur Dioxide SOSO22

(725 ft(725 ft33/hr) x (1028 Btu/ft/hr) x (1028 Btu/ft33) / 1000000 ) / 1000000 = .7453 mmBtu/hr= .7453 mmBtu/hr

(0.000588 lb/mmBtu) x (.7453 mmBtu/hr) (0.000588 lb/mmBtu) x (.7453 mmBtu/hr) = 0.000438 lb/hr= 0.000438 lb/hr

(0.000438 lb/hr) x (8760 hr/yr) = (0.000438 lb/hr) x (8760 hr/yr) = 3.839509 lb/yr3.839509 lb/yr

(3.839509 lb/yr) / (2000 lb/ton) (3.839509 lb/yr) / (2000 lb/ton) = .001919 tpy = .001919 tpy

Final Calculated Emission Rates and Emission Rate Final Calculated Emission Rates and Emission Rate

Limits for the Induction generator.Limits for the Induction generator.

  

Pollutant Emission Rate Limit (tons/year)

Calculated Emissions for a single cogeneration set (tons/year)

Calculated Emissions (single)/Limit

Calculated Emissions for two cogeneration sets (tons/year)

Calculated Emissions (two)/Limit

Carbon monoxide

100 27.7427 3.6046 54.4854 1.8353

Nitrogen dioxide

10 14.2187 0.7032 28.4374 0.3516

Sulfur dioxide 10 0.0019 5263.16 0.0038 2631.5789

Particulate matter (PM10)

10 0.0002517 39729.8371 0.0005034 19864.9186

Volatile organic compounds

10 0.2774 36.0490 0.5548 18.0245

Lead 0.6 -------- -------- -------- --------

Total 100 42.2717 2.3657 84.5434 1.1828

ConclusionConclusion

The emission rates for The emission rates for nitrogen dioxide exceed the nitrogen dioxide exceed the exemption level listed in 9VAC exemption level listed in 9VAC 5-80-11E. Therefore, the 5-80-11E. Therefore, the installation of one or more installation of one or more generators would require a generators would require a permit under 9VAC 5-80-10. permit under 9VAC 5-80-10.

Obtaining a Permit For the Obtaining a Permit For the Induction GeneratorInduction Generator

A form 7 is an application for A form 7 is an application for an air permit for new and an air permit for new and modified source permits and modified source permits and state operating permitsstate operating permits

AcknowledgementsAcknowledgements We would like to thank Warren Heidt for We would like to thank Warren Heidt for

the opportunity to complete this project. the opportunity to complete this project. We would also like to thank him for all of We would also like to thank him for all of the help and guidance that he gave to us the help and guidance that he gave to us over the last three semesters.over the last three semesters.

  

Acknowledgements Cont.Acknowledgements Cont.

We would also like to thank We would also like to thank Dr. Klevickis for all of her help Dr. Klevickis for all of her help putting this project together. putting this project together. She kept a close eye on us She kept a close eye on us through these past three through these past three semesters and made sure that semesters and made sure that we stayed on the right track.we stayed on the right track.