OPTIMISING THE UPGRADING PROCESS...
Transcript of OPTIMISING THE UPGRADING PROCESS...
MD EMEA DR. THOMAS BUER
OPTIMISING THE UPGRADING PROCESS OF BIOGAS GLOBAL BIOMETHANE CONGRESS 2012, BRUSSELS
Szarvas, Hungary Wastes & Energy Crops BGA RÖBLINGEN, CHICKEN MANURE
UTS Company Profile Technical Trends Optimising the digestion process Overcoming Feedstock management issues (quality & quantity) Discussion
CONTENT
UTS Company Profile
Söhnergy, Germany Energy Crops
COMPANY PROFILE
Founded in 1992 115 employees in Europe 65 in North America (parent company Anaergia Inc.)
German parent company with 100% UK & Ireland, Spain, Italy subsidiary, HU JV, PL, Ro and Gr under preparation (future markets)
Private ownership: Dr. Andrew Benedek via Anaergia Inc. 19 years experience in design & build
biogas plants & technology Technology provider to > 1,600 biogas plants with own
products and manufacturing Design & Build of > 220 turn-key biogas plants Biogas plants from 75 kW to > 5 MW for agricultural wastes, energy crops, commercial and industrial organic wastes & municipal waste,
municipal power plants Representation in 11 European countries Currently about 40 active projects in 9 European countries
DE, IT, UK, PL, GR, ES, HR, RO, HU, International revenue percentage > 50%
UTS IN EUROPE
Spain /Portugal /France • GM • Sales • Operations
UK & Ireland: • GM • Sales • Operations • Service
Italy: • GM • Sales • Operations • Service
Germany: • MD • Sales • Operations • Service • Products
CEE Poland • Sales • Operations Romania • Sales
Hungary: • GM • Sales • Operations
Greece: • Sales • Project Development
Croatia: • Sales • PM
HQ & KEY PROJECTS EUROPE
Hallbergmoos - HQ
HU: Szarvas 4.2 MWel
HR Mala I&II 2 MWel
UK Glenfarg, 0.8 Mwel 16 kta waste
DE Soehnrgy 1MWel 350 Nm³h CH4
DE Bieringen 0.8 MWel
IT: Marchesina 1 MWel
DE: Roeblingen 700 Nm³
UTS CORE TECHNOLOGY Patented and trade know-how protected core products
Hydraulic mixers Service box with roof configuration feeder system and controls Separator pumps
Biogas process design PFD Layout and overall design
Helios/Triton/Kairos Process and component design P&ID Controls (PLC, software code)
UTS VISION AND VALUES
We are committed to reducing the World’s Carbon Footprint by being a Global Leader in
Sustainable and Economical Distributed Energy Generation from Waste.
TECHNICAL TRENDS (… REFLECTING ECONOMIC BOUNDARIES)
Bieringen, Germany Energy Crops
Mid to long term lower feed-in tariffs Rising „fuel‚ costs for maize etc Political debate using food for energy production Increased use of wastes
(cap on maize % in Germany and new Italian FiT) Flexible plants for various substrate rather than bonus optimized plants
(dependency on mono-substrates over plant lifetime)
MARKET TRENDS I
ECONOMIC BOUNDARIES
Biogas Plant Invest 3000 – 6500 €/kWh Civils 45 % Equipment 55 % Deprec. 7 – 15 a Equipment 15 – 30 a civils Equity 25 – 45 % Loan 3.5% - 9 % Labor 0.5 – 1 ct/kWh Power 0.5 – 1 ct/kWh Service 1.5 – 2.5 ct/kWh Loan for land
Feedstock Energy Crops 15 … 40 €/t Manure 0 … 15 €/t Wastes +50 …- 50 €/t Transport !
Energy Output Electricity 4 ... 7 ct/kWh market price Gas 5 … 7 ct/kWh market price Heat 0.5 … 4 ct/kWh local contract FiT Electr. 9 … 28 ct/kWh @ 5 … 26 a FiT Gas … 12 ct/kWh
Digestate EC & Manure: 0 …- 5 €/t Wastes - 5€/t… + 5€/t Transport!
CASE 1: ENERGY CROP POWERED BIOGAS PLANT
CAPEX Construction € 4.000.000 Amortisation € 266.667 Financial costs € 145.184 OPEX Operation € 242.505 Manpower € 31.285 Machine € 16.619 G&A € 89.573 Raw Material € 863.093 Total cost € 1.654.927 Revenue € 2.181.267 EBIT € 526.340 ROI 13,16%
ASSUMPTIONS: 1 MW PLANT 28 CT/KWH FIT @ 15 A (ITALY) 90% AVAILABILITY, 7.875 H/A,
7.875 MWH DEPRECIATION 15 A 25% EQUITY/75% LOAN @ 4.9% 21.500 T/A SUBSTRATES @ 32% DS, 96% VSS, 660 L/KG
VSS, 40 €/T CAPEX: 5.23 CT/KWH OPEX: 4.83 CT/KWH TOTAL W/O FS 10.06 CT/KWH FEEDSTOCK: 10.96 CT/KWH TOTAL: 21.02 CT/KWH
CASE 2: ORGANIC WASTE POWERED BIOGAS PLANT
CAPEX Construction € 5.625.000 Amortisation € 375.000 Financial costs € 170.156 OPEX Operation € 242.505 Manpower € 90.000 Machine € 20.000 G&A € 113.000 Total Costs € 1.010.661
Revenue FiT € 1.134.000 Revenue Feedstock/Waste € 720.000 Costs Waste Disposal € - 180.000 EBIT € 663.339 ROI 11.79%
Assumptions: 0.8 MW plant 18 ct/kWh FiT (UK) 90% availability, 7.875 h/a,
6.300 MWh Depreciation 15 a 45% Equity/55% loan @ 5.5% 18.000 t/a organic waste @ 25% DS 90% vSS, 700 l/kg
vSS, - 40 €/t CAPEX: 8.65 ct/kWh OPEX: 7.39 ct/kWh Total w/o FS 16.04 ct/kWh Feedstock: -8.57 ct/kWh Total: 7.47 ct/kWh
Power distribution & peak management Energy production in biogas plants independent from out of control
factors wind/sun Biogas plants operation matching „grid demand‚ vs. high uptime to
ensure profitability Gas to Grid (using gas grid for storage) …larger plants > 2 MW (Triton)
Large or external gas covers 2nd CHP for peaking
MARKET TRENDS II
BIOGAS = ENERGY TO STORE AND REGULATE
BIOGAS PLANT SZARVAS CUSTOMER: AUFWIND - BAYWA INSTALLED CAPACITY: 4.2 MWEL, 10 MW PRIMARY ENERGY SUBSTRATES: ORG. WASTES, MANURE, CROPS, MUNICIPAL SLUDGE, SLAUGHTERHOUSE WASTE, AND AGRICULTURAL WASTE TO ENERGY REACTOR CONCEPT: HELIOS
TECHNICAL DETAILS: CHP installed: 3 x 1.190 kWel 1 x 600 kWel Electrical Output: 4.170 kWel Thermal Output: 4.135 kWel Net Electricity production: per Year about 26.200.00 kWh (feed-in capacity) Net Heat Production: per year about 25.500.00 kWh Substrate Solids: Sweet Sorghum, Manure Process Sludge (44.000 t/a) Reception Pit 1: Pig Slurry (33.000 t/a) Reception Pit 2: Slaughterhouse Wastes, Whey (45.000 t/a)
SZARVAS PROJECT DATA
„CLASSICAL‚ & FLEXIBLE BIOGAS PLANT
CHP
100%
External Heat Use 15-30%
Sale to
Grid 40%
Electrical Energy 40%
Thermal Energy 40 %
Biogas Plant Fermenter 1
0
Biogas Plant
Fermenter 2
Biogas Plant Fermenter 1
Biogas Plant
Fermenter 2
100%
Internal heat consumption approx. 10-25%
CHP 1
50- 100%
External Heat Use ? ? ?
Sale to
Grid 40%
Electrical Energy 40%
Thermal Energy 20 - 40 %
0
50-100%
CHP 2
50 - 100% Sale to
Grid 40%
Electrical Energy 40% 0
0-100%
Internal heat consumption approx. 10-25%
4 – 6 h
2 x (4 – 6 h) = 8 – 12 h
Optimizing the Digestion Process
Glenfarg, UK Food Waste
HOW IS BIOGAS BEING PRODUCED?
Org. material
Air tight tank
Decomposition of org. material
Acid-forming bacteria Methane-forming bacteria
Retention time ~ 10 – 60 days
EXPERIENCE WITH MULITPLE FEEDSTOCKS
Pig manure
Cow manure
Slaughterhouse waste
Corn silage
Organic waste
Biogas yield in l/kg vSS
Stillage
0
100
200
300
400
500
600
700
800
900
sewage sludge
Pig manure
Cow manure
Stillage
Organic waste
Sewage sludge
EXPERIENCE WITH MULTIPLE FEEDSTOCKS
Pig manure
Cow manure
Slaughterhouse waste
Corn silage
Organic waste
Biogas yield in m³/t of fresh material
Stillage
Sewage:
5 % DSM @ 70 % vSS
400 l/kg vSS -> 14 m³/t
UTS TRITON ® Preferred design for large plants (> 1 MW) Ring-in-ring arrangement of tanks Outer ring: high rate reactor Inner ring: post-reactor Concrete cover or gas membrane/storage Capacity: 1.8 – 2 MW/system vs. 0.8-1.0 MW Short piping length Low energy losses (5-10% vs. 20-30% therm) Compact construction (-30% footprint) Clean and straight forward plant design
rather than tank/reactor farms Low peristaltic energy consumption due to optimized circular plug flow
(< 7%, less dissipation) Circular and directed flow
TRITON® VS. CONVENTIONAL TECHNOLOGY
8MW conventional
80m
110m
140m
90m
Z Z
BB
B BB B B B
S
V
S
ZNFSF NFSF
ZNFSF NFSF
ZF F ZF F
SF SF SF SF
V
V V
SS
Typical non-Triton 4 MW plant Triton 4 MW plant
- 30% footprint !
MANTOVAAGRICOLTURA, 1 MW - EXPANSION, WITH 2ND 1 MW INSTALLATION, ITALY
TRITON
CONVENTIONAL
Overcoming Substrate Management Challenges
Mantova, Italy Energy Crop & Slaughterhouse Waste
DOS & DON‘TS OVERCOMING FEEDSTOCK MANAGEMENT CHALLENGES
DOS DON‘TS
Flexible plant design for various substrates (mixing, pre-mixing tanks, volumen)
Recirculation of digestate Long term contracts or partial ownership of land Screening/batch tests Contaminants check Secure => 80% mid to long term supply for base
load Biological healthy substrate mix
Spot substrate market: caution! No quality check of input material Mono-substrates: caution: nutrient management
SUMMARY Trend to larger plants with increase use of various organic wastes (250-500 kW 1 MW and above)
Flexible plants including power on demand production of electricity or gas to grid
Technology evolution from „farm‚-style plants towards industrial style power plants Efficient & reliable design Higher technical advancements (equipment, PLC/Scada) Safety regulations (maintenance!) Professional and safe operation
Discussion &
THANK YOU FOR YOUR ATTENTION !
Fair Oaks, US Gas upgrading to vehicle fuel (CNG)
BGA BIERINGEN • 800 KWel Plant - • Start Construction June 2010 • Client: • Biogaspark Neckar-Odenwald • Turn-key UTS-Triton Biogasplant • Energy crops (corn silage)
BGA BIERINGEN
TRITON® CONCEPT FOR 18 MW
39/27 x 9 m Inner ring with membrane roof
GLENFARG 3D- LAYOUT
Buffer tank V1 Post Fermenter N1
Fermenter F1
Equipment Building
TEG GLENFARG
Depackaging and feed transfer pump
EQ / Hydrolisis buffer tank
Fermenter I/II top view
BIOGAS PLANT GLENFARG
TEG - GLENFARG
Final digestate storage tank with gas storage
Hygenisation Station
BIOGAS PLANT GLENFARG