A Case Study of the Design Calculation for a Logical Biogas Plant

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1 Appendix I A Case Study of the Design Calculation for a Logical Biogas Plant As already mentioned, the Sugar Cane & Byproducts Development Company produces about 7.6 million tonnes sugar cane and 2.4 million tonnes bagasse annually. At present, about 1.5 million tonnes of this bagasse is destroyed. Annually a part of this bagasse, it is assumed may be used as a substrate in anaerobic digestion bioreactor for biogas production. Moreover, assumed that biogas produced is used as fuel in CP. With this assumption, based on the daily rate of biogas and some additional assumptions, such as M s of bioreactor will consider 5 Mg/d of liquid manure, 4 Mg/d of bagasse, and 2.5 Mg/d of feed stack from residues storage (Abdoli, 2004); the equipment of a complete biogas plant can be designed as follows: Preparation tank The preparation tank will be a vertical cylindrical container of concrete. In the preparation tank, only the daily liquid manure will be stored for t RPT (residence time in preparation tank)=10 days in order to carry out cleaning and maintenance work at the bioreactor. The density of the liquid manure ρ s =ρ w. A factor f VPT =1.25 shall be assumed to take into consideration the volume for air and fixtures. The relationship between height () and diameter (D) of the tank shall be PT /D PT =2.

2 Volume: V M.( t / ). f (5 Mg / d).(10 d /1000 kg / m ).(1.25) 62.5m PT s RPT s VPT That grams) M s : mass rate of substrate, f VPT : factor to increase the preparation tank, (Note: Mg= a million eight: PT 6.8m, Diameter: D PT.4m, The Pump for preparation tank In the preparation tank a centrifugal pump with a wide chamber and a submerged motor shall be installed. The pump of the preparation tank shall be able to deliver V P 10m /h liquid manure to the bioreactor or to pump the complete volume of the bioreactor (V =41m as calculated below) within t I (time for discharging the reactor content)=5h (given below). Its efficiency is assumed to be η VP =0.5. Its pressure head shall be 1 bar. V 10 m / h or Throughput: P 1 p RPT V V / t 41 m / 5h 86 m / h 2

3 Pressure head: P P 1bar, Capacity of the motor: actual: P V. P / 0.6 kw; 1 P P p P Nominal:. / P V P kw p p P P Reservoir for bagasse The extra bagasse produced in sugar cane process is assumed about M b 165Mg. The average density of bagasse is ρ b =0.15Mg/m. The bagasse is compressed and stored in the reservoir. Reservoir Volume: V M s / s 165 Mg / a / 0.15 Mg / m 1100m s Width: W s 10m, eight: s.5m, Length: L s 2m Reservoir conveyors Two screw conveyors in series with nominal capacity V SC 1 m / h each and motor capacity P SC =5kW transport bagasse from the reservoir to the preparation tank twice a day for t SC =1h/d.

4 Total power of the two screw conveyors: (P SC ) tot =2P SC.2.t SC /24h = 2.5kW.2.1h/24h=0.8kW Bioreactor A vertical cylindrical tank of concrete shall be used as bioreactor. The residence time of the substrate in the bioreactor shall be t =0days. A factor f V (factor to increase the bioreactor volume) = 1.25 has to be chosen to take into consideration the volume for air and fixtures in the bioreactor. The completely filled bioreactor shall be emptied within t 1 =5h at a flow rate of v 1 =0.5m/s. The relation between height and diameter of the bioreactor shall be /D =1/2. Two propeller-agitators (Outer diameter of agitator D AG =0.5m, Newton number Ne AG =0.5(residence force to inertia power), revolution n AG =150rpm) shall be installed for intermittent mixing and breaking off the floating layer with a working period of t AG =5min/h. Both agitators are equipped with submerged motors and their height shall be adjustable by chains. Volume: V M t f Mg d kg m s / s.. V (11.5 / ) / (1000 / ) 0d m eight: 5.5m. Diameter: D 10m, The volume load of this medium-size bioreactor is then B =DM /V = 1571 kg odm (organic Dry Matter)/d/41m=.64kg odm/m.d.

5 The average volume load for small plants is B =1.5kg odm/m.d and of large plants is B =5 kg odm/m.d. Diameter of the discharge pipe: D V / t / v.4 / [(41 m / 5 h) / (0.5 m / s).(4 / )] 0.m I 1 1 Capacity per agitator drive: P AG =1..Ne AG.ρ G.(n AG ).(D AG ) 5 = kg/m. (150.π/0).(0.5) 5 m 5 =78.7kW=80kW Power consumption of both agitators: ( PAG ) tot 2. PAG. t AG 2.80kW.5 min/ h 1. 4kW eating (pipes) For effective fermentation, mesophilic temperatures shall be chosen at T 50 C. The lowest outside temperature in winter is T A 10 C. The substrate has a specific heat capacity of CP SU, 4.2kJ / kg. C has thus to be heated from 20C to 50C, So, 0 C. T SU The bioreactor walls shall be insulated with a layer of polystyrene that is 0.1 m thick. The heat transmission coefficient of polystyrene is K 0.05W / m. K. Although the substrate surface does not reach the ceiling of the bioreactor, the complete wall will be taken into consideration when calculating the heat losses; heat losses through the ceiling are negligibly low, because the ceiling is in contact with gas and /or air inside and outside.

6 The heat transfer coefficients inside at the wet bioreactor wall shall be assumed to be (h ) i =4000W/m 2.C for agitated liquid and outside to (h ) o =400W/m 2.C for humid soil; Then U- factor can be calculated: U 1/(( h ) S / K ( h ) ) 1/(1/ / 0.051/ 400) i o 2 0.5W / m. C The maximum temperature difference between substrate and environment is T T T A ( 50 C) (10 C) 40 C The heating medium (warm water) shall cool down from temperature difference can be calculated: T E 70 C to 60 C and the T A T T E T A 10 C The flow rate of the heating medium in the heating pipe shall be v =1 m/s. The heat transfer coefficient inside and outside the heating pipes have been assumed to be the same 2 h h 400W / m. C i o for slowly flowing liquid; the heating pipe is a good heatconductor and therefore negligible in the calculation; then the k-factor for the heating pipe wall would be: h 1/(1/(( h ) i ( h 2 ) ) 1/(1/ 4001/ 400) 200W / m. C o The average temperature difference between heating medium and substrate in the bioreactor is T B ( T T ) / 2 T 15 C E A Design

7 eat for heating the substrate: Q M. C. T (115 Mg / d).(4.2 kj / kg. C).(0 K) 17kW SU s p, SU SU Surface area of the bioreactor, which conducts heat: A 2 2. D / 4. D. 250m eat losses of the reactor: Q h A T W m C m C kw (0.5 /. ).(250 ).(40 ) 5 Necessary heat: QN QSU Q 17kW 5kW 22kW Necessary heating liquid QSupply for heat supply to the bioreactor: Q Q / ( C.. ) 22 kw.600 s / h Supply v w w (4.2 /. ).(1000 / ).(10 ) 1.88 / kj kg C kg m C m h Diameter of the heating pipe: D Q v m h m s s h m P ( Supply /.4 / [(1.88 / ) / (1 / ).(4 / ).(600 / )] Length of the heating pipe: L Q h T D kw W m C C m m 2 P v / (. B.. P ) 22 /[(200 /. ).(15 ).( )] 25

8 Aeration Aeration with an airflow rate V a referring to the biogas flow rate V V is V of a / 0.04 sufficient for desulphurization. Oil-free compressed air shall be blown in at a pressure of p h2 =6 bar. The velocity of the air in the air pipe shall be v a = 2m/s. Blown in air: V V V V m d Nm h a a /. (0.04).(976 / ) 1.6 / Diameter of the air pipe: Da V v Nm h m s m ( a / a.4 / ) [(1.6 / ) / (2 / ).(4 / )] 0.02 Compressor Compressor with pressure vessel of volume V c = 0.05m Volume rate of the compressor: V C 1.7 Nm / h Pressure head from P C1 =1 bar to P C2 =6 bar (there is to be assumed friction in the pipe)

9 Capacity of the compressor: P C =0.5kw Gasholder A low-pressure gasholder of plastic foil will be used, in this example. The relationship of the volume of the bioreactor to the volume of the gasholder shall be (V /V Gh )= 1:2. The ratio V /V Gh is the usual value (between 1:1 and 1:). Volume of the gasholder: V Gh =V / (V /V Gh ) =41/ (1/2)= 862m The gasholder enables the storage of the biogas production of nearly 1 day. Engine The biogas-energy content shall be E biogas 6kWh / m. The biogas plant should be equipped with an ignition oil engine in the CP. 9% by weight of ignition oil shall be added to the biogas in a ratio of M OIL / M The energy content of the ignition oil is E OIL 10kWh / kg. Efficiency of the engine: Electrical efficiency: 0% e

10 Thermal efficiency: 50% th Consumption of ignition oil assuming a density of the biogas of 1.11kg / m : M V. (976 m / d).(1.11 kg / m ) 108 kg / d M OIL M.( M O / M ) (108 kg / d).(0.09) 97.6 kg / d Yield of energy: E E. V E. M tot biogas OIL OIL [(6 kwh / m ).(976 m / d) (10 kwh / kg).(97.6 kg / d) / (24 h / d)] 284kW E E kW e tot e E E kW th tot th Nominal capacity of the engine with a reserve of 0%: E=111kW Residue storage tank A vertical cylindrical tank of concrete shall be used as residue storage tank. The residence time of all residue in the storage tank shall be t Res =100d. It has to be taken into consideration that some water ( V Re s 2.5 m / d ) from the residue tank is fed back into the bioreactor. A factor f Vres =1.1 is chosen to take into consideration the volume for air and fixtures in the storage tank. The storage tank shall have the same height as the bioreactor.

11 Volume: V M s V t f Mg d Mg m m d Re s ( / Res). Re s. V Re s [(11.5 / ) / (1 / ) 2.5 / )] 100d.1.1=990m eight: Res =5.5m Diameter: D Res =15m

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