biowalk4biofuels project: from algae and...

BioWALK4Biofuels project:

FROM ALGAE AND BIOWASTE

to 2nd GENERATION BIOMETHANE.

Examining the potential for Biomethane in

Italy

Roberto Renda; Brussells – 9/10 October 2012

DICMA, University of Rome “La Sapienza” –

[email protected]

GLOBAL BIOMETHANE CONGRESS 2012 Brussells – 9-10 october 2012

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mailto:[email protected]

DICMA (Italy) Faculty of Engineering Department of Chemical Engineering

Material and Environment (coordinator)

CoNISMa (Italy) National Interuniversity Consortium for Ocean Sciences

Ecoil (Italy)

NERI (Denmark) National Environmental Research Institute, Aarhus University

DTI (Denmark) Danish Technological Institute

CSMCRI (India) Central Salt & Marine Chemicals Research Institute

NGVAEurope (Spain) Natural Gas Vehicle Association

SGtS (Sweden) Scandinavian Gas Treatment Service

HU (Jordan) Hashemite University

RTU (Latvia) Riga Technical University

AP (India) Aquagri Process Pvt Ltd

PV (Italy) Power Ventures 2

Critical points to be solved

Energy demand

CO2 Emissions

Eutrophication

•Green house gases

•Exhaust gases

•CO2

•NOX

•Sox

•agro-industrial

Subproduct

Eutrophication agents

•N, P, K

BIOWASTE 2nd generation Biofuels

Biogas

Biomethane

Anaerobic Digestion

umidity > 70%,

• C/N = 15 ÷30

ALGAE

Photosynthesis

efficiency (10% - 12%)

•Terrestrial Plants (3%-

5%)

Biomass production:

•N, P, K ; Light ;CO2

Umidity =80%

C/N = 20

Low lignin

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The project aims to demonstrate on a pre-industrial scale:

- Cultivation of macro algae in open ponds (600 kg/day);

- Production of protoplasts to feed Algae Broth;

- Treatment of bio waste (Target 21 kg N/day, 3 kg P/day);

- Optimize a two phase Anaerobic digestion plant supplied

partially by Macro algae (25-40 m3/h);

- Production of bio-fertilizer;

- Production of bio methane even on small scale plant (max

300kW);

- Conversion of an existing truck diesel engine to dual fuel.

PROJECT OBJECTIVES

WHERE THE B4B PLANT IS PLACED ?

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ALGAE CULTIVATION POOLS

CO2

N

SunLight

Biogas

Algae

Whey

Manure

GAS

RECOLLECTION

SYSTEM

Connection to the

CHEMINEE

9

Steam

Generator

room

Pond 1 Pond 4

1 m3 1

m3

1 m3 1 m3

N, P

Toward ponds

2 3

FAN

Combined gas&

washed manure

Mixing system

GAS RECOLLECTION AND DISTRIBUTION SCHEME

WP3

Just few pictures

FLOW RATE

BOILER 1: 14.700 m 3/h

BOILER 2: 12.700 m 3/h

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S.No Species Carbohydrate

(% DW)

Protein

(% DW)

Lipid

(% DW)

Moisture

( %)

Chlorophyta

19. Ulva 56.07±2.68b 18.57±1.82 2.00±0.20 89.98±0.7

Proximate composition of different seaweeds

Results obtained by Indian Partners CSMCRI & AP

Species Daily Growth

Rate (%)

U. lactuca 27.6 ± 2.31

Ulva lactuca

Species Protoplasts

yield

(cells/g fresh

wt.)

Protoplasts

Regeneration Rate

(%)

U. lactuca 4.0 ± 0.5× 108 94 ± 0.8

Isolated protoplasts Calcofluor stained protoplasts

Protoplasts yield and regeneration rate

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Blowing Flue gas = blowing CO2

GDR = 15% - 21% higher than atm. Air

Addition of flue gas/CO2 may increase areal yield by 33-36%

Manure is as good nutrient as conventional fertiliser

Good C:N:P ratio for biogas production

Results from pilot scale plant in Denmark

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Ulva species test “on site” by Conisma & Ecoil

Autoctonous Ulva seaweeds selected in Augusta harbour

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With hens manure Without manure

Time to test results in a pre-industrial scale plant

Algae species selected: Ulva lactuga & laetervirens cultivated and

harvested in open ponds

Planned the interface between all plant sections

Obtained all authorization for the realization of the plant

Found Availble biomass and established transport contracts

Tested hens manure as algae fertilizer and biomass to digest

Tested direct blowing of flue gas from industrial steam generator

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ONCE THAT:

FLOATING PONDS ASSEMBLY

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HARVESTING TECHNOLOGY

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Manual harvest usually adopted in India and Africa also to

keep intact the organoleptic properties

B4B R&D activities:

RoboHARV

Equipped with two floater

Collects algae to the corner

Easily removed by pumps

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NEW DESIGN

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PLANT DESCRIPTION

Total volume: 160 m3

Footprint approx. 120 m2

The purpose of this plant is to digest about 1.000 kg/day of raw poultry

manure mixed with algal biomass and to produce 1 kWep

per each Kilogram of raw manure, recovering combustion CO2 in algae

pond.

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N° 2 Tanks : m 2,50 ø – m 6,20 h

CSTR

Cohibented

Feed rate

From 5 to 24 m3/day

Solids’ concentration from 5 to 20 %

HRT and SRT adjustable

Temperature range: from 30°C to 85°C

Possibility to work: separately or in series

Hydrolysis stage

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N° 1 basin: m 6,0x2,4x4,0 h

Cohibented

Archimedes RBC

Volume: 22 m3

Active surface: 5.500 m2

Feed rate

From 5 to 24 m3/day

Dissolved solids’ concentration from 5 to 20 %

Temperature range: from 30°C to 55°C

Expected biogas production: from 200 to 350 m3/day

HRT adjustable

Methanation stage

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N° 1 basin: m 3,0 x 2,4 x 2,8 h

Archimedes RBC

Volume: 11 m3

Active surface: 2.750 m2

COD removal: 50 kg/day max

Nitrogen removal: complete denitrification respecting COD charge limits

Possibility of feeding algae pond without nitrification (ammonia) or

without denitrification (nitrates)

Wastewater treatment

PLANT

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Average a 600 cow farm produce:

HIDROLISYS

PONDS

METHANATION

PREPARATION

HOMOGENIZATION TREATMENT PLANT

CHP

FROM BIOGAS TO BIOMETHANE

CRIOGENIC UPGRADING TO LBG

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• LBG producer/distributor independent on the availability of consumers at

the end of the pipeline.

• LBG can be more easily transported to stored in respect to CBG

• The same energy quantity is contained in a volume 600 times smaller

LBG has a 2.4 time higher calorific value then CBG

• Vehicles which use LBG have a larger radius of action

• LBG has a weight of 420g/l and is composed for more than 98% of CH4

• LBG reduces the NOx emission to almost zero

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B4B PROJECT FIRST HYPOTESIS

UPGRADING UNIT DATA:

• 10 Nm3/h for LBG production

• Consumption 20 - 34 kW

• To high energy request for a 25-40 m3/h biogas plant for a production of

200 liters/day (80% of the overall electric production)

• No storage for LBG furnished

• No stakeholders

• No availability to distribute LBG for free to the LNG station because of

too far from the B4B plant (From Sicily to the North of Italy)

• No possibility to distribute a so small quantity of LBG even monthly

• In the end any possibility to make LNG in a such little scale 10 m3/h

SMALL SCALE PLANT FIND A FINAL USER FOR LBG

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B4B PROJECT SECOND HYPOTESIS

UPGRADING UNIT DATA:

10 [Nm3/h] unit for the cryogenic production of CBG

• Consumption 15 - 25 [kW]

• Storage for CBG (furnished)

• Stakeholders & final users

• Availability to produce and distribute on CBG

• Reached project objectives?

• to develop a cost effective solution to be applied in the Italian agro-

industrial field

PROBABLY

- Biomethane requires incentives to make profitable its production.

SMALL SCALE PLANT FIND A FINAL USER (CBG)

CBG and dual fuels

a possible solution for agro-industry

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B4B project foreseen to modify a track with a dynamic Injection (diesel +

CBG)

“Diesel dual fuel” (DDF) refers to an engine working with diesel and gas

simultaneously

In a DDF system the engine can still run 100% diesel fuel

CBG and Diesel Dual Fuel

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What B4B plant needs:

• Constant Feeding of the plant with agro-industrial biowaste (once

a week)

• What B4B plant can do:

• Supply the track with CBG while receiving the biomass (35

kg/Week)

• Available, practical and effective solution for agro-industry

B4B Life Cycle Impact Assessment:

Fossil fuel consumption

• Reduction of fuel

consumption up to

34%

• All scenarios absolve

the same function

Consumption unit

[tep]

Life Cycle Impact Assessment:

Green house gases

Reduction up to 35% - 75%

All scenarios absolve the same function

Emissions unit

[ton CO2 equivalent]

Biogas v/s Biomethane? B4B case study

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FEED IN TARIFF:

FOR BIOGAS PLANTS SINCE THE 1st JENUARY 2013 D.M.

6/07/2012 (GOVERNEMENTAL LAW)

•BIOMASS FEEDING: Sub-product Table 1A

•INSTALLED POWER: 1<P<300 kW

•BASE FEED IN TARIFF: 236 €/MWh

•BONUS (-60% N-REMOVAL & CHP): 30 €/MWh

•20 YEAR INCENTIVES

•THEORETICAL B4B CONFIGURATION INCENTIVES: 266 €/MWh

45 kWe CHP (ELECTRICITY PRODUCTION)

25 m3/h of Biogas (65% CH4)

45 kWe/h * 8000 h/y = 360.000 kWh

360 MWh * 266 €/MWh= 95.760 €/year

Maintainance 50.000 €/year : transports, etc…

No interesting Payback Time >8 year

CHP B4B case study

B4B PROJECT

IS A RTD PROTOTYPE AND

IS NOT ALLOWED TO

REQUESTS ANY INCENTIVES.

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100 kWe CHP (ELECTRICITY PRODUCTION)

50 m3/h of Biogas (65% CH4)

100 kWe/h * 8000 h/y = 800.000 kWh

800 MWh * 266 €/MWh= 212.800 €/year

Theoretical cost 1.000.000 €

Net profit 186.176 €/y

No transport costs (inside the farm)

Electricity costs 0,15 €/kWh * 8 kWh/h * 8000

h/y= 9.600 €/year

maintenance cost 9% (very conservative)

9% financial interest

PBT < 5 100 kW biogas

plant works

CHP 2XB4B case study

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Biomethane? B4B case study

25 m3/h of Biogas (65% CH4) to CBG

17 m3/h CH4 = 12,75 kg/h

12,75 kg/h * 1 €/kg = 12,75 €/h

8000 h/year * 11,475 €/h = 102,000 €/year

Maintainance 25% of the profit (Electricity 26.000 €/year)

PBT >10 years

Taxes for transportation use (around 4,47€ / 1.000 kg)= 1032 €/year

Electricity costs 0,15 €/kWh * 22 kWh/h * 8000 h/y= 26.000 €/year

Complete of a refueling station 220 bar (PSA upgrading system)

GRID INJECTION – (Low pressure 0,5 bar)

12,75 kg/h * 0,43 €/kg = 5,44 €/h

8000 h/year * 5,44 €/h = 43,520 €/year


Maintainance costs (pipe rent 3.000 €; electricity 18.000€/year )

Upgrading & Compression consumption 8-15 kW

AD Plant section average consumption 6 kW

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Biomethane? 2 X B4B (100 kWe)

50 m3/h of Biogas (65% CH4) to CBG

32,5 m3/h CH4 = 24,5 kg/h (appr.) // 195 ton/y

24,5 kg/h * 1 €/kg = 24,5 €/h

8000 h/year * 24,5 €/h = 196,000 €/year

Plant cost: 1.200.000 € - Net profit 129.360 €/year

Maintainance 34% (El. 26%)

PBT >10 years (9% fin. Interest)

Taxes for transport use (around 4,47€ / 1.000 kg)= 871 €/year


Equipped with a refueling station 220 bar

GRID INJECTION – LOW pressure

24,5 kg/h * 0,43 €/kg = 10,53 €/h

8000 h/year * 10,53 €/h = 84,280 €/year


Consumption of 32 kW for upgrading & Compression

AD plant section average Consumption 10 kW

Biogas v/s Biomethane? 2 X B4B (on going)

50 m3/h - 100 kWe CHP (ELECTRICITY PRODUCTION)

800 MWh * 266 €/MWh= 212.800 €/year

Maintainance 12,5% (El. 9.600€/year 4,5%)

Net Profit: 186,176 €/year – PBT <5 years

Incentive equivalent 0,425 €/m3 (1 Sm3 > 1,6 kWhe)

(GRID INJECTION) - Low pressure

8000 h/year * 10,53 €/h = 84,280 €/year

Maintainance 45% (El. 31.200€/year 37%)

Net Profit: 38.000 €/y – PBT >10 years

Min. feed in tariff 0,76 €/kg * 195 ton/year = 148.176 €/year 36

Pla

nt cost:

1.2

00.0

00 €

50 m3/h – (CBG PRODUCTION + REFUELING STATION )

8000 h/year * 24,5 €/h = 196,000 €/year

Maintainance 34% (El. 50.400€/year 26%))

Net Profit: 129,360 €/year - PBT >10 years

Min. feed in tariff 0,30 €/kg *195 ton/year = 56,816 €/year

Pla

nt cost:

1.0

00.0

00

€

CONCLUSIONS

CURRENTLY THE PRACTICAL WAY TO DEVELOP BIOGAS IN

ITALY IS TRHOUGHT CHP

BIG OPPORTUNITY FOR “DIESEL DUAL FUEL” VEHICLE

RETROFITTING AND BIOMETHANE USE FOR AGRO-

INDUSTRIAL FIELD

NEED TO WORK TO MAKE SUGGESTIONS TO POLICY

MAKERS TO PRODUCE ADEQUATE INCENTIVES FOR:

TRANSPORTATION CBG

UPGRADED BIOGAS GRID INJECTION

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THANKS!

FOR:

INFORMATION- DETAILS – SUGGESTION – FURTHER REQUESTS –

PROPOSAL – NEW PROJECT ETC ETC…

PLEASE CONTACT

http://www.biowalk4biofuels.eu

[email protected]

[email protected]








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