optimising the upgrading process...
TRANSCRIPT
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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
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UTS Company Profile Technical Trends Optimising the digestion process Overcoming Feedstock management issues (quality & quantity) Discussion
CONTENT
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UTS Company Profile
Söhnergy, Germany Energy Crops
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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%
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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
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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
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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)
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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.
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TECHNICAL TRENDS (… REFLECTING ECONOMIC BOUNDARIES)
Bieringen, Germany Energy Crops
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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
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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!
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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
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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
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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
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BIOGAS = ENERGY TO STORE AND REGULATE
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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
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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
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„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
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Optimizing the Digestion Process
Glenfarg, UK Food Waste
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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
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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
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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
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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
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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 !
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MANTOVAAGRICOLTURA, 1 MW - EXPANSION, WITH 2ND 1 MW INSTALLATION, ITALY
TRITON
CONVENTIONAL
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Overcoming Substrate Management Challenges
Mantova, Italy Energy Crop & Slaughterhouse Waste
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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
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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
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Discussion &
THANK YOU FOR YOUR ATTENTION !
Fair Oaks, US Gas upgrading to vehicle fuel (CNG)
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BGA BIERINGEN • 800 KWel Plant - • Start Construction June 2010 • Client: • Biogaspark Neckar-Odenwald • Turn-key UTS-Triton Biogasplant • Energy crops (corn silage)
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BGA BIERINGEN
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TRITON® CONCEPT FOR 18 MW
39/27 x 9 m Inner ring with membrane roof
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GLENFARG 3D- LAYOUT
Buffer tank V1 Post Fermenter N1
Fermenter F1
Equipment Building
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TEG GLENFARG
Depackaging and feed transfer pump
EQ / Hydrolisis buffer tank
Fermenter I/II top view
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BIOGAS PLANT GLENFARG
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TEG - GLENFARG
Final digestate storage tank with gas storage
Hygenisation Station
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BIOGAS PLANT GLENFARG