The Uilenkraal

Bio-gas Power Generation Plant

Dr. Andrew Taylor

Cape Advanced Engineering (Pty) Ltd

andrewtaylor@cae.co.za

4 October 2015

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CAPE ADVANCED ENGINEERING (PTY) LTD 2

the South African realitytypical Eskom winter profile - 2015

peak from 4 pm to 9 pm – no sun for solar – wind ?

17 hours of peaking capacity is required

no sun

no sun

peak sun

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CAPE ADVANCED ENGINEERING (PTY) LTD 3

Uilenkraal project investment motivation –

the 2003 RE White Paper• Supply shortage predicted from 2006 – LOAD SHEDDING

• an Energy Policy is a Constitutional requirement !

• the stated problems problems not emphasised

– coal dependence - water issues ?

– greenhouse gasses - unemployment ?

– energy security - food cost & food security ?

• acknowledged “local entrepreneurship & innovativeness”

• 10-year target “10 000 GW.hr generated by 2013” and 1.7

GW operational in 2013.

• “early win” targets included bio-mass combustion (sugar

and wood) and solar water heating

• bio-mass was prominent (combustion prominent ?)

• technology development was encouraged !

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CAPE ADVANCED ENGINEERING (PTY) LTD 4

then the NERSA REFIT programme

• 2nd quarter 2009 REFIT I announced

• 4th quarter 2009 REFIT II announced – incl. bio-gas

• 31 December 2009 – REFIT Gazetted

but without any provision for bio-gas – why ?

• 1st quarter of 2011 – REFIT disbanded – why ?

• August 2011 – REIPPP initiated

– no provision for bio-gas – why ?

• 5 November 2012 – Financial closure on 1st round of

wind and solar projects, then rounds 2, 3 and 4

• still no provision for bio-gas - why ?

• then foreign intervention by the UN and GIZ etc.

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CAPE ADVANCED ENGINEERING (PTY) LTD 5

cost comparison with REIPPP Round 1

• REIPPP round 1 involved 28 projects

• 1,416 MW for a total investment of US$ 5.97 billion

• 18 PV technology – installed capacity of 632 MW

• 2 CSP technology – installed capacity of 150 MW

• 8 wind technology – installed capacity of 634 MW

• average cost of each project = R 2.763 billion per

project

• average cost of installed capacity = R 55 million per

MW installed

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CAPE ADVANCED ENGINEERING (PTY) LTD 6

cost comparison with REIPPP Round 1

• average cost = R 55 million per MW “capacity” installed

• if solar PV projects yield of 20% of installed capacity,

and if wind projects yield of 30%

• then average yield of round 1 ~ 24.5%

• then average actual cost of solar & wind = R223

million per MW generated (the true cost of “effective

capacity”)

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CAPE ADVANCED ENGINEERING (PTY) LTD 7

bio-gas power in Germanysame power output as new SA coal plants (when running at full capacity)

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CAPE ADVANCED ENGINEERING (PTY) LTD 8

renewable energy in Germanybio-mass generates more than wind and solar combined

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CAPE ADVANCED ENGINEERING (PTY) LTD 9

bio-gas in SA in 2015• projects still denied access to the national grid–REIPPP?

• Durban landfill project – highly successful

• Johannnesburg Water – bio-gas from waste water

• City of Windhoek – bio-gas from waste water (CAE)

• CAE Uilenkraal project in Darling –

technical success @ <50% utilisation (project by CAE)

• proven capital cost in South Africa

< R20 million per MW for landfill projects R1.35 / kW.hr

< R30 million per MW for bio-gas projects R1.65 / kW.hr

• far cheaper than wind & solar & generate at peak times

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CAPE ADVANCED ENGINEERING (PTY) LTD 10

the Uilenkraal dairy farma large scale total mixed ration (TMR) dairy

• 1500 Lactating cows in milk

• high roof open barns (180m)

• “free stall” animal

accommodation

• commercial animal feed mill

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CAPE ADVANCED ENGINEERING (PTY) LTD 11

without grid access, power off-take is critical

• the commercial animal feed mill – peak demand 750 kVA

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CAPE ADVANCED ENGINEERING (PTY) LTD 12

local technology and design

Developed and

Manufactured in

South Africa

• Hybrid, mixed and heated plug flow bio-digester

• Locally built bio-gas engines and CHP units

bio-digester construction – local materials

• > 7000 ton capacity

• 1% to 14% solids

• 20 to 40 day retention time

• Sequential plug-flow process

the bio-gas & fertiliser plant

Anaerobic

bio-digester

Manure & waste

water mixing

Scraped manure collection Bio-Gas Generator (CHP)

Liquid bio-fertiliser storage

for land applicationSolids separator

FlareHeat to bio-

digester

Biogas to

generator

Biogas

to Flare

Electricity

Out

Bio-fertiliser

outCattle bedding

or bio-fertiliser

Solids

Liquid

Manure

& waste water slurry

in

Process heat out

for food processing

X

2 x 250 kVA bio-gas CHP generatorsDeveloped and

Manufactured in

South Africa

bio-gas plant generators – 22 litre V12

bio-gas plant electrical systems – 1 MVA

Developed and

Manufactured in

South Africa

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CAPE ADVANCED ENGINEERING (PTY) LTD 19

Average load profile - Jan and Feb 2015NB: min. set to 5 kW, peak hourly demand = 406 kW (briefly 455 kW)

0

50

100

150

200

250

300

350

400

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Po

we

r [k

W]

Time of Day

Uilenkraal Bio-Gas January and February

V12007 V12008 Eskom Bio-Gas TOTAL

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CAPE ADVANCED ENGINEERING (PTY) LTD 20

98%

74%

bio-fertiliser – solid & liquid

Thank you for your interest

Dr. Andrew Taylor

Cape Advanced Engineering (Pty) Ltd

andrewtaylor@cae.co.za

4 October 2015