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Event:

One day event by Cogeneration Association of India at

Kisanveer Sahakari Sakhar Karkhana Ltd. (Bhuinj) dt. 17.09.2019

Presented By

Mr. K.Mohan Kumar

(Deputy General Manager & HOD – Process & Environment)

Green Fuel Generation (Biogas) Green Fuel Generation (Biogas) ––Press MudPress Mud

Fuel

Fodder

Fertilizer Raw Material

Fertilizer

Alcohol Production

Bagasse

Cane Tops and Leaves

Press Mud /Filter Mud

Furnace ash

Molasses

13-18% Fibre

Upto 15% Sugar

Tops and leaves

Fibre

Sugar to market

Sugarcane

BY -PRODUCTS FROM SUGAR INDUSTRY

2

By-Products

Press Mud to Bio-CNG

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BIOGASBIOGAS

Methane (55-60%),

Carbon Dioxide (40-45%),

Hydrogen Sulphide (0.3%)

Moisture(1%)

Hydrogen, Nitrogen, Ammonia

<<<%

Biogas is a combustible gaseous fuel that is collected from the microbial degradation of organic matter in anaerobic conditions Raw biogas Temperature (32-40 Deg. C) The biogas technology is being promoted by Ministry of New and Renewable Energy Composition of Biogas

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WORLD HISTORY OF BIOGAS

1808 – Sir Humphrey Davy

found that methane was present in the gases that is

formed by the Anaerobic

Digestion of manure

1884 – Louis Pasteur student, Ulysse Gayon,

performed the anaerobic fermentation of manure and water at 35ºC and obtained

100 liters of Biogas per cubic meter of Manure.

1895 – Biogas is used to light

up the streets in Exeter, England

1957 – A British Inventor, Bates, modifies

his car to run on Biogas

produced from pig manure.

2005 – The Biogas Support

program in Nepal wins the Ashden

Reward for installing over

150,000 Biogas Plants in rural

areas and a Biogas powered train starts it's

service in Sweden

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03 04

01 02

Equipments that are used for Transfer of Feed Stock from Yard to the Biogas Plant

Feedstock Storage Transfer Feedstock

preparation tank, pH Dosing Tank, transfer Pumps

Feedstock Preparation

H2S removal, Carbon Dioxide removal, Moisture removal

Biogas Purification and Upgradation

Solid and Liquid Manure Storage and Selling

Digestate and Slurry handling System

Compression and cascade storage structure

Biogas Compression and Distribution System

05 06

PRESS MUD TO BIO-CNG

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Anaerobic Digester Nutrients for digester system , Flaring system for biogas

Biogas Generation System

TYPICAL SCHEME

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FEEDSTOCK

– Anaerobic digestion is the natural biological process which stabilizes organic waste in the absence of air and transforms it into bio-fertilizer and biogas. This Organic waste is called “Feedstock”

– Types of Feedstock in Sugar and Distilleries

Press Mud:- Press mud traditionally is used as manure through bio-compost process by spraying spent wash on press mud.

Bagasse

Sugarcane Trash

Napier Grass

Food Waste

Spent Wash Source: Internet-For Illustration only

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FEEDSTOCK STORAGE AND TRANSFER

• Biogas substrates are typically moist, which can make them difficult to store because bacteria and mould can grow on them

• Storage is an issue because many of the feedstocks accumulate seasonally, such as Press mud and Baggase, but need to be stored cheaply for the whole year

• This not only causes substrate loss, but can lead to strong odour emissions, and the toxins and spores formed can pose a risk to workers.

• Different storage and stabilisation options have been developed

• Silos, Bunkers in RCC

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FEEDSTOCK PREPARATION

1. Feedstock Preparation

§ WHY

§ HOW

Faster Anaerobic fermentation

Potentially increase biogas yield Homogenising Feed

Make use of locally available substrate

Mechanical Shear, heat, pressure and electric fields

Thermal Heating

Chemical Alkali, Acid, Solvent addition

Biological Adding Substrates and/ or Enzyme and/or Microbes

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DIGESTOR

Digester is a vessel or container where the breaking down of organic material takes place

Classification of Digester based on following:-

By temperature:

- Mesophilic (35°C)

- Thermophilic (55°C)

By operation:

- Batch

- Continuous

- Fed-batch or semi-continuous

By water content of input material:

- Wet systems: TS content < 15% Dry Solids

- “Dry” systems: TS content 25-50% Dry Solids

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Complex organic matter Carbohydrates, proteins, fats

Complex organic matter Carbohydrates, proteins, fats

Soluble organic molecules

Sugars, amino acids, fatty acids

Soluble organic molecules

Sugars, amino acids, fatty acids

Volatile fatty acids

Volatile fatty acids

H2CO2 H2CO2

CH4 + CO2 CH4 + CO2

Acetic acid Acetic acid

1 1

2 2

3 3

4 4 4 4

Hydrolysis

Acidogenesis (Fermentation)

Acetogenesis

Methanogenesis

ANAEROBIC DIGESTION PROCESS

The use of a biogas upgrading or purification process in which the raw biogas stream like CO2, H2S and moisture are absorbed or scrubbed off, leaving above 90% methane per unit volume of gas.

• Presence of CO2 in biogas poses following problems: – It lowers the power output from the engine; – It takes up space when biogas is compressed and stored in cylinder; – It can cause freezing problems at valves and metering points where the compressed gas undergoes

expansion during engine running.

• The traces of H2S produces H2SO4 which corrode the internals of pipes, fittings etc. • Moisture causes corrosion and decreases heating value of the fuel.

• As per IS 16087:2016 and the OMC requirement decides the units

• Elemental Sulphur is produced as byproduct from the H2S scrubbing System – Dewatering Equipment separates

• Carbon Di Oxide can be liquefied and marketed

BIOGAS UPGRADING

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COMPRESSED BIOGAS VS COMPRESSED NATURAL GAS

Properties Compressed Natural Gas (As per IS 15958:2012)

Upgraded Biogas (As per IS 16087:2016)

Raw Biogas

Composition % (v/v)

CH4 – 89.14% CO2 – 4.38% H2 – .01% N2 – .11%

CH4 – 90%* CO2 – 4% CO2+N2+O2 -0.5% TS (including H2S) -20 mg/m3 Moisture < 5 mg * Technologies can provide upto 97% gradation

CH4 – 55- 65% CO2 – 35-45% H2 – .02% N2 – 1.98% H2S – 500 ppm

Lower Heating Value

44.39 MJ/kg 42.62 MJ/kg 20.5 MJ/kg

Relative Density 0.765 0.714 1.014

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DIFFERENT TECHNOLOGIES FOR UPGRADATION

Methods

Parameters

High pressure

water scrubbing

Chemical

absorption

Pressure swing

absorption

Membrane

separation

Cryogenic

Gas Pre Cleaning

Requirement

No Yes Yes Yes Yes

Working Pressure 9-10 Bar 1 Bar 4 – 7 bar 4-7 bar 40 bar

Methane Loss 1– 2 % 1-2 % 1-9 % 10 - 15 % 1-2%

% purity attained

of upgraded Biogas

95-98 % Upto 99 % 95 - 99 % Upto 90 % Upto 99 %

Heat requirement - Required - - -

Operating Cost Low Moderate Moderate Low High

Initial Cost Low Moderate Moderate Moderate High

Process Handling Easy Complex Easy Easy Complex

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DIGESTATE HANDLING

• Digestate (slurry) from the Digester is further concentrated in Dewatering Unit

• Part of the liquid Digestate is recirculated to the Feed tank

• Bio-Fertilizer (Solid Fertilizer& remaining Liquid Fertilizers) are further upgraded

• Upgrading and conditioning help in storage, transport, and application.

• Further Solids-Liquid Separation

• Moisture reduction –Composting, Drying

• Pelleting

• Nutrient Addition

• Marketing and supply management of Bio-fertilizers

Source: Internet-For Illustration only

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BIOGAS COMPRESSION & STORAGE

• Biogas compressors are readily available in the local market in the range of 2.5 bar up to 200 bars.

• Depending on the application a suitable compressor can be chosen.

– High Pressure compressor,

– Cascade of storage cylinders

• Compressed and stored in Cylinders

• The compressed and stored biogas in cylinders can be used for various purposes

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BIOGAS USE

Upgraded Biogas

Transportation Fuel for Vehicles

Cooking -Biogas Stoves

Compressed & Bottled Biogas

Injection into Natural Biogas

Raw Biogas

Electricity Production

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TYPICAL MASS BALANCE

Typical Mass Balance

Courtesy : M/s.Quantum Green

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OVERALL BENEFITS

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Feasibility Study

Feedstock availability throughout the year

Feedstock storage for long time and its implication on characteristics

Marketing and Selling of the Digestate

BIO-CNG Saleability

Any CNG line nearby

Any CNG terminal / Filling Station nearby

Bio-CNG –Cooking Gas Cylinder feasibility

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Environmentally Friendly EASY HANDLING AND DISPOSAL OF PRESS MUD

RENEWABLE FUEL

LESS POLLUTION-GREEN FUEL

Farmer Friendly ProductsLIQUID MANURE

SOLID MANURE

ELEMENTAL SULPHUR (FERTILIZER)

BIO-CNG PRODCUTION

REVENUE GENERATING

BY-PRODUCTS (MANURES, S,CO2)

ORGANIC PRODUCTS

SUSTAINABLE , RENEWABLE

ENERGY

CONCLUSION-PRESS MUD TO BIO CNGCONCLUSION-PRESS MUD TO BIO CNG

INCOME

Waste to Wealth

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