Efficient Biogas utilization systems

Transcription

1 Efficient Biogas utilization systems CHP systems and auxiliaries Jakarta

2 GTP Solutions GmbH GTP employees have build together more than 500 plants in the fields of gas treatment and Cogeneration with gas engines We have project experience in landfill gas and biogas since 1994 We are a group of people working in a flexible team Mechanical, electrical and process engineers Main actual markets: Germany, East Europe, South America Future markets with focus on South-East-Asia!!!

3 All project phases GTP - From the first project idea to the official hand over of the installation Project idea - feasibility Design and procurement Turn key plant

4 Solutions for Energy Fix layout and design, procurement and delivery of decentralised energy plants Includes CHP systems and auxiliaries Gas engines Various gas sources Gas treatment systems (e.g. drying, H 2 S removal) Booster and flares Heat recovery systems Layout of connection to boiler systems Steam generators, hot water or other process heat Ice water production Electricity feed in to grid

5 Different gas sources Biogas Landfill gas Natural gas

6 Solutions of GTP GTP - Know-how Partner in the field of Cogeneration, landfill and biogas technology Basic Package Standard Package Premium Package Technical base layout of entire plant - concept study development Detail Engineering of all components Additional to Basic Procurement and delivery of key components Supply Chain Management because we know all important suppliers for CHP auxiliaries since years Additional to Standard Assembly of all mechanical works Assembly of all electrical works Project management Hand over of Turn-key plant

7 Biogas from POM capacity 60t FFB/h Depending on process inside mill, the waste water can have different COD level per 1 m 3 (different biogas potential) Depending on type of biogas reactor (covered lagoon or UASB type) the biogas produced per ton of COD is different. Different biogas output Range of methane produced With 9 m 3 CH 4 / t (FFB) Electrical production (41,5%) 6 to 12 m 3 CH 4 / t (FFB) 540 m 3 / h (5.400 kw) kw el. / h Operation hours / year kwh With FIT of Sumatra (MV) 975 IDR/kWh el Mio. IDR / year (equivalent with ,- Euro/year)

8 Reason for plant shut-down (renewable gas sources) Electrical failures 30% 10% Other 30% Mechanical 30% Gas quality

9 Biogas composition from POME Biogas from anaerobic digestion of POME Main components and trace substances: Methan % Carbon dioxide % Nitrogen about 5 % Oxygen about 2 % Hydrogen sulfide (H 2 S) (protein in feedstock) ( ppm) Other Harmful substances, Si, Cl, dust can be also present!

10 Influence of H 2 S on technical equipment (I) corrosion inside gas engine (more frequent revisions) Damage of the cylinder, valves, spark plugs (parts change more frequently) Acid impact of the lubricating oil (oil change more frequently) Sediments in the exhaust gas system e.g. heat exchanger (Damage of components) Deactivation of the catalyst (Damage of components) Increased sulfur emissions in the exhaust gas (harmful for environment) Finally H 2 S is Strong smelling, high toxic

11 Influence of H 2 S on technical equipment (II) Exhaust gas temperature was below the dew point. Exhaust gas heat exchanger with sulphur sediments. In this case total damage

12 Piston with silicon damage

13 Cylinder head with silicon damage

14 Conclusion Harmful components decrease lifetime of engine, spare parts and lube oil. Finally it costs additional money (O&M, lifetime, failures)!!! Next steps: 1. Quantify these additional maintenance costs 2. Define the best technical treatment system for the specific problem (here H 2 S, Si or others) 3. Quantify additional investment and maintenance costs for these gas treatment system 4. Compare between additional expenses for treatment system and savings on the extension of O&M + lifetime cycles and less failures Example: H 2 S Treatment system for 2 x 1,16 MW machines on biogas: ,- Euro More cost engine service - biogas without treatment: 2x3,50 Euro/Oh Total savings on maintenance with Oh / a: ,- Euro/a Pay back period: between 3 and 4 years

15 Example: Treatment of biogas and exhaust-gas Biogas cooling / drying Biogas cleaning Exhaust gas cleaning Cooling biogas to <8 C Re-heating of biogas to 25 C temperature Drying effect Remaining moisture rel % Cleaning H 2 S In this case acrtivated carbon Cleaning other harmful substances, for example Si, NH 3 Catalytic treatment of exhaust gas Reaction temperature app. 400 C

16 Gas cleaning landfill gas (Italy) Gas cleaning system with gas drying and activated carbon Gas engine containerised 1MW with booster

17 Biogas plant household waste treatment system (Spain) Gas cleaning and drying unit Booster and emergency flare Gas engine containerized co-generation power plant 716 kw el Steam production from exhaust gas and direct fired steam boiler (oil or natural gas)

18 Biogas plant in a starch factory (Thailand) Gas drying system with booster H 2 S removal system (biological system) Containerized co-generation power plant with 2 gas engines in total 2,7 MW el

19 Short summary GTP creates overall layout of CHP systems e.g. gas engines, heat recovery systems, flares, booster and biogas treatment technology. GTP know how to combine all these technologies (of entire project). Customers and partners benefit from the long-term experience of GTP in different applications of CHP (since 1994 busy in this field). GTP team works together with a strong local partner In order to reach - > Successful operating projects!!!

20 Advantages for final customers Delivery of German know-how from first hand Delivery of quality components (for long-term operation) Create max. local delivery content (whole mechanical and electrical assembly by local partner company) For customer this is max. cost efficient (but not cheap!!!): Because German know-how mixed with max. local content guaranties competitive prices. Nearly all customer requested solutions can be realized Thanks for your attention Any Questions?