Expert training train the trainer

Transcription

1 Expert training train the trainer Berry de Jong (CCS)

2 Content 1. Introduction Business case scenarios Principles of the tool Sizing of components Investment curves Gross/nett production Investment example 2. Case-study Digester properties 3. Type of digester 4. Day-fresh manure Stable modifications 5. Storage 6. Energy substitution, energy export and internal energy use 7. Flare 8. Investment overview 9. Financial results 10. Cash flow overview 11. Digestate treatment 12. Tips and tricks 2

3 Introduction 3

4 Business case scenarios: 1. Biogas Sell biogas/heat from biogas with biogas network 2. Heat Sell heat from biogas with heat network 3. CHP Compensate own energy use and sell electricity 4. Biomethane Feed-in (and sell) biomethane to grid 5. Digestate treatment Avoid (expensive) transport and disposal of manure, produce fertilizer 4

5 Principles (1) Scale kwe / tons input Wet digestion CSTR (Continuously stirred tank reactor) Concrete/polyester tank Mesophilic Bottom up calculation Size of components Investments Operational heat and electricity use 5

6 Principles (2) Bottom up calculations Defining size of components Digester : Nett (useful) volume (m³) CHP : Electric capacity (kwe) Boiler : Thermal capacity (kwth) Storage : Nett volume (m³) Piping : Capacity AND Distance Investments Investment curves based on size 6

7 Principles (3) Bottom up calculations Defining output Predefined gas yields of all substrates Efficiency of utilization technique at defined capacity Bottom up calculations of energy use Defining Costs Maintenance : Defined per component (investmentor predefined curve) Personel : Hours per component Insurance : % of total investment 7

8 Investment example: CHP 8

9 CHP capacity 300 dairy cows Production digester ~ m³ biogas 55% CH 4 ~ m³ methane GJ or MWh P fuel = 180 kw 10% overcapacity P fuel,chp = 200 kw 9

10 Efficiency [-] CHP efficiency Efficiency changes with capacity 0,45 0, ,35 0,3 0,25 0, Capacity [kwe] Efficiency small CHP 10

11 Efficiency [-] Overall CHP efficiency Overall efficiency 85% 0,6 Radiation losses 5-7% Exhaust gasses up to 8-10% 0,55 0,5 η th =47,5 % 0,45 0,4 0,35 η e =37,5 % 0,3 P fuel = 200 kw 0, Fuel input [kw] Thermal efficiency Electrical efficiency 11

12 Investment [ ] Investments P e = P fuel x η e = 200 x 0,37 = 75 kw e CHP Investement Capacity (Pe) [kwe] ASUE 2014 biogas ASUE

13 Maintenance Oil & Filters Spark plugs and other filters Revision Breakdowns 13

14 Maintenance costs [ /kwhe] Maintenance 0,080 0,070 0,060 0,050 0,040 0,030 ASUE 0,020 0, Capacity (Pe) [kwe] 14

15 Digester properties 15

16 Case 1 Dairy farm in the Netherlands 275 cows, liquid manure 35 calves, liquid manure 35 yearlings, liquid manure Question 1: Find digester size (volume) for this biogas plant 16

17 Question 1 17

18 Case 1 Dairy farm in the Netherlands 275 cows, liquid manure 35 calves, liquid manure 35 yearlings, liquid manure Question 2: Add ½ ton per day maize silage Find digester size (volume) for this biogas plant 18

19 Question 2 19

20 Case 1 Dairy farm in the Netherlands 275 cows, liquid manure 35 calves, liquid manure 35 yearlings, liquid manure Question 3: Add liquid substrates instead of solid substrates Notice changes ODM Digester size DM input 20

21 Question 3 21

22 Digester properties Digester size is defined by: Retention times are predefined for every substrate E.g. Manure days E.g. Maize silage 40 days E.g. Liquid substrates < 20 days Maximum retention time defines retention time for all substrates Maximum ODM load, capped at 3,5 kg/m³.day Substrate variables are adjustable per region by country admin Substrates can be added by user Digester size can be overwritten Layout (investments) changes when (co)substrates are added Mixing pit (Size) Grinder pump (solid substrates) Storage (pre storage and digestate storage) 22

23 Type of digester Type of digester A Horizontal digester liquid manure 23

24 Energy [kwth] Heat losses (1) Energy use digester Max Horizontal CSTR Heating substrates Losses through Biogas Losses thourgh Floor Losses thourgh Walls Losses through Roof 24

25 Heat losses (2) CSTR Tower digester 25

26 Energy [kwth] Heat losses (3) Energy use digester Max Average Max CSTR Horizontal Tower Vertical/Tower Heating substrates Losses through Biogas Losses thourgh Floor Losses thourgh Walls Losses through Roof 26

27 Energy [kwth] Heat losses (4) Innovative roofs New innovations will reduce the heat losses through membrane roofs However a membrane roof will always have large losses Heat recovery digestate Energy use digester Max Average Max CSTR Horizontal Tower Vertical/Tower Heating substrates Losses through Biogas Losses thourgh Floor Losses thourgh Walls Losses through Roof 27

28 Energy [kwth] Type of digester 60 Both CSTR and tower digester are Innovative roofs 50 incorporated in the tool in terms of heat 40 losses. 30 For investment costs, only CSTR (horizontal) 20 digesters are considered. New innovations will reduce the heat losses through membrane roofs However a membrane roof will always have large losses 10 0 Heat recovery digestate Energy use digester Max Average Max CSTR Horizontal Tower Vertical/Tower Heating substrates Losses through Biogas Losses thourgh Floor Losses thourgh Walls Losses through Roof 28

29 Day fresh manure Day-fresh manure [yes or no] Yes No 29

30 Day fresh manure Day-fresh and non day-fresh biogas potential is included in the database Specify livestock Specify Type of manure Day-fresh manure [Species] [type of animal] [Solid or Liquid] [yes or no] Cows Dairy cows Liquid manure Yes Cows Young dairy cows (calf <1 year) Liquid manure No Cows Young dairy cows (yearling >1 yea Liquid manure No 30

31 Stable floor modifications (1) Traditionally slatted floors Slatted floors not suited for day-fresh manure production Modifications may be beneficial to the case 31

32 Stable floor modifications (2) Investments for (simple) modifications to produce day-fresh manure included in the tool for dairy cows Closed floor system Scrapers Pre-storage Pumps Make stable modifications to produce fresh manure? Yes 32

33 Stable floor modifications (3) Investments for (simple) modifications to produce day-fresh manure are included in the tool for dairy cows Make stable modifications to produce fresh manure? Yes 33

34 GHG emissions [ton CO2 eq/year] Reduced stable emissions from the storage of digestate instead of fresh manure 100 GHG emissions biogas plant Methane slib CHP Avoided emissions from heat Avoided emissions from electricity Reduced stable emissions

35 Stable floor modifications (4) Changing the stable floors and manure management has impact on day-to-day operations on the farm Other factors, apart from producing fresh manure for the biogas plant, may be just as important 35

36 First results Optimal case: What if all (nett) energy produced by the biogas plant can by used to replace fossil fuels (natural gas and electricity) 36

37 Storage 37

38 Storage (1) Mixing pit (stable modifications or cosubstrates) Separate digestate storage Cosubstrate storage (additional) Capacity Storage time needed Storage capacity needed Available storage on farm Additional storage needed Foil basin for digestate Polyester silo for liquid cosubstrates Trench silo for solid cosubstrates Default: Only additional storage for adding cosubstrates is added 38

39 Storage (2) 39

40 Storage (3) Storage Storage: Fresh manure and digestate (digested manure) have to be stored separately. Please indicate the storage type you want to include in thi Storage type All digestate Default/Required How long do you need to store the digestate 7 [months/year] Available separate storage capacity digestate [m³] Default/Required Available How long do you want to store the cosubstrates 3 [months/year] Available storage capacity liquid cosubstrates 13 [m³] Available Available storage capacity solid cosubstrates - [m³] Available Default/Required Database value (min 7 months storage) Calculation of required storage Based on storage type Fill in available storage on the farm Model will automatically add investment for extra capacity 40

41 Storage (4) Storage Storage: Fresh manure and digestate (digested manure) have to be stored separately. Please indicate the storage type you want to include in thi Storage type All digestate Default/Required How long do you need to store the digestate 7 [months/year] Available separate storage capacity digestate [m³] Default/Required Available How long do you want to store the cosubstrates 3 [months/year] Available storage capacity liquid cosubstrates 13 [m³] Available Available storage capacity solid cosubstrates - [m³] Available All digestate Calculation of required storage Fill in available storage on the farm Model will automatically add investment for extra capacity 41

42 Storage (5) Storage Storage: Fresh manure and digestate (digested manure) have to be stored separately. Please indicate the storage type you want to include in thi Storage type All digestate Default/Required How long do you need to store the digestate 7 [months/year] Available separate storage capacity digestate [m³] Default/Required Available How long do you want to store the cosubstrates 3 [months/year] Available storage capacity liquid cosubstrates 13 [m³] Available Available storage capacity solid cosubstrates - [m³] Available Model will automatically add investment for extra capacity 42

43 Investment [EURO] Storage (6) Digestate storage Gas tide storage (Germany) Pored concrete (gas tide) Concrete modules (gas tide) Steel (gas tide) RVS (gas tide) Foil bassin Capacity [m³] 43

44 Investment [EURO] Storage (7) Digestate storage Factor 4! Pored concrete (gas tide) Concrete modules (gas tide) Steel (gas tide) RVS (gas tide) Foil bassin Capacity [m³] 44

45 Energy substitution, export and energy use of the biogas plant 45

46 Energy substitution or export 1. Energy use of the farm 2. Energy use of nearby energy user 3. Energy supply to energy user 1. Distance 2. Complexity of the trajectory 3. Third party export 5. Gas grid connection (Biomethane) 1. Pressure in gas grid 2. Distance to gas grid 3. Complexity of the trajectory 6. Default energy prices per country/region 4. CHP Electricity that can not be substituted is fed in to the grid 46

47 Energy substitution Energy that can be substituted by energy from the biogas plant Energy use of the farm Energy use of nearby energy user Electricity Heat Electricity that can not be substituted is fed in to the grid Heat that can not be substituted is wasted! Energy use that can be substituted Energy Source Specify amount Unit Price per unit [#] Default Overwrite Unit Electricity [kwh/year] 0,10 [EUR/kWh] Natural Gas [m³/year] 0,52 [EUR/m³] 47

48 Energy export Third party export more expensive Permits Planning Energy supply Distance to heat/gas user [km] Compexity of traject 0,2 [km] 0,0 [0 1] The complexity of the trajectory is [0] for pipes through open fields, and [1] for urban Energy export to third party? Yes areas. Please specify the complexity for the Distance to gas grid 0,00 [km] Compexity of traject 0,0 [0 1] Pressure in gas grid 0,11 [bar (g)] chosen trajectory. 48

49 Biomethane Grid feed-in Distance to grid Pressure in grid low pressure grids are possible Energy supply Distance to heat/gas user [km] Compexity of traject 0,20 [km] 0,5 [0 1] The complexity of the trajectory is [0] for pipes through open fields, and [1] for urban Energy export to third party? Yes areas. Please specify the complexity for the Distance to gas grid 0,20 [km] Compexity of traject 0,5 [0 1] Pressure in gas grid 0,11 [bar (g)] chosen trajectory. 49

50 Complexity of trajectory Rural vs Urban Appendages and fittings Ground work Gas network Heat network Default complexity: 0,5 50

51 Energy [kwth] Wood chips or biogas to heat the digester Mono-manure 75 kwe Energy use digester % Depending on local conditions Horizontal Biogas production CHP Exhaust losses Electric power CHP Thermal power CHP Biogas production Losses through Roof Losses thourgh Walls Losses thourgh Floor Losses through Biogas Heating substrates The digester needs heat to operate, what medium do you want to use? Using part of the biogas to supply heat, may affect the profit. Produce heat using Biogas Default Overwrite Price of wood chips 40 [EUR/ton] 51

52 Wood chips or biogas to heat the digester Using wood chips to heat the digester can be beneficial for the case Depending on Price of wood chips CAPEX and OPEX wood chips boiler Exploitation subsidies of the biogas plant 52

53 Tool Default energy prices per country/region and subsidies can be overwritten Energy use that can be substituted Energy supply Energy Source Specify amount Unit Price per unit Distance to heat/gas user [km] 0,2 [km] The complexity of the trajectory is [0] for [#] [EUR] Default Compexity of traject 0,0 [0 1] Electricity [kwh/year] 0,10 [EUR/kWh] pipes through open fields, and [1] for urban Natural Gas [m³/year] 0,52 [EUR/m³] Energy export to third party? Yes areas. Please specify the complexity for the Feed-in tariff Feed-in tariff Electricity Feed-in tariff biomethane feed-in Price per unit [EUR] Default 0,05 [EUR/kWh] 0,32 [EUR/kWh] Distance to gas grid 0,00 [km] chosen trajectory. Compexity of traject 0,0 [0 1] Pressure in gas grid 0,11 [bar (g)] Default CHP Electricity subsidy 0,11 [EUR/kWh] CHP Heat subsidy 0,11 [EUR/kWh] Biomethane subsidy 0,09 [EUR/kWh] Heat subsidy 0,06 [EUR/kWh] The digester needs heat to operate, what medium do you want to use? Using part of the biogas to supply heat, may affect the profit. Produce heat using Biogas Default Price of wood chips 40 [EUR/ton] 53

54 GHG emission [kg CO2 eq] Flare Mandatory in some countries Country specific indicator GHG emission from flaring 1 days production 75 kwe biogas plant km vs km - Pressure valve (Methane) Flare (CO2) Mid Sized car (12,5 gr/km) 54

55 Investments 55

56 Investment subsidies (1) Investment subsidy Specify maximum total investment subsidy available [ ] Or percentage of total investment [% ] Scenarios Case [EUR] Biogas Heat CHP Biomethane Investments [EUR] Investment subsidy [EUR] Subsidy percentage [%] Own contribution [EUR] Ann. Benefits [EUR/year] Ann. Costs [EUR/year] Ann. Profit [EUR/year] Simple payback time [Years] 56

57 Investment subsidies (2) Investment subsidy Specify maximum total investment subsidy available [ ] Or percentage of total investment 50 [% ] Scenarios Case [EUR] Biogas Heat CHP Biomethane Investments [EUR] Investment subsidy [EUR] Subsidy percentage [%] Own contribution [EUR] Ann. Benefits [EUR/year] Ann. Costs [EUR/year] Ann. Profit [EUR/year] Simple payback time [Years] 57

58 Investment subsidies (3) Investment subsidy Specify maximum total investment subsidy available [ ] Or percentage of total investment 50 [% ] Scenarios Case [EUR] Biogas Heat CHP Biomethane Investments [EUR] Investment subsidy [EUR] Subsidy percentage [%] Own contribution [EUR] Ann. Benefits [EUR/year] Ann. Costs [EUR/year] Ann. Profit [EUR/year] Simple payback time [Years] 58

59 Investments (1) Overview per component Possibility to overwrite Add component 59

60 Investments (2) overview Investments Biogas Heat CHP Biomethane Digestate treatment Overwrite Digester/Biogas plant 622 [m³] Storage [m³] CHP 75 [kwe] Biogas Boiler on site [kw] Biogas Boiler at end-user 145 [kw] Gas upgrade installation 17 [m³/hour] Gas network 1,50 [km] Heat network 1,50 [km] Connection to grid 17 [m³/hr] Separator Centrifuge Dryer Flare 33 [m³/hour] Parteurization Pre-storage 0 [m³] Stable floor 160 [m²] Scraper 160 [m²] Add investement: Extra investment Total hardware Civil works [m²] Advice & permits Contingency Startup costs Total investment Investment subsidy Can be changed at the firs Own contribution

61 Investments (3) Overwrite investments Investments Biogas Heat CHP Biomethane Digestate treatment Overwrite Digester/Biogas plant 622 [m³] Storage [m³] CHP 75 [kwe] Biogas Boiler on site [kw] Biogas Boiler at end-user 145 [kw] Gas upgrade installation 17 [m³/hour] Gas network 1,50 [km] Heat network 1,50 [km] Connection to grid 17 [m³/hr] Separator Centrifuge Dryer Flare 33 [m³/hour] Parteurization Pre-storage 0 [m³] Stable floor 160 [m²] Scraper 160 [m²] Add investement: Extra investment Total hardware Civil works [m²] Advice & permits Contingency Startup costs Total investment Investment subsidy Can be changed at the firs Own contribution

62 Financial results 62

63 Financial results & add costs Ann. Benefits Biogas Heat CHP Biomethane Digestate treatment Avoided purchase of fossil fuel purch [EUR/year] Sale of electricity [EUR/year] Avoided purchase of electricity [EUR/year] Sale of Biomethane [EUR/year] Exploitation subsidies [EUR/year] Total benefits [EUR/year] Ann. Costs Biogas Heat CHP Biomethane Digestate treatment Electricity purchase [EUR/year] Wood chips purchase [EUR/year] Active carbon [EUR/year] Biomass purchase [EUR/year] Export of digestate [EUR/year] Added: Extra costs [EUR/year] Personell error [EUR/year] Maintenance error [EUR/year] Insurance error [EUR/year] Annuity [EUR/year] Total costs error [EUR/year] Add costs Type of costs Amount Unit [EUR/year] 63

64 Financial results Biogas Heat CHP Biomethane Digestate treatment Total investment [EUR] Investment subsidy [EUR] Own contribution [EUR] Ann. Profit [EUR/year] Write-off/depreciation [EUR/year] Simple payback time [Years] Net present value [EUR] Biogas Heat CHP Biomethane Digestate treatment 64

65 Cash flow Production year 1 70% Production year 2 90% Production year 3 100% Select scenario Redemption Biogas Annuity 65

66 Digestate treatment 66

67 Digestate treatment (1) Nitrogen surplus in Europe (source: JRC, European Commission) 67

68 Digestate treatment (2) Avoid export of manure Treatment technologies in BioEnergy Farm 2 Separation Sanitation/pasteurization Nitrogen stripping (not commercial yet) Struvite production (not commercial yet) Drying (not for small scale) Membrane separation 68

69 Digestate treatment (3) Land use Placement Nitrogen [kg N] Placement Phosphate [kg P2O5] Processing obligations [kg P2O5] Nitrogen Surplus [kg N] Phosphate Surplus [kg P205] This is equal to: Manure Surplus Nitrogen [ton Manure] Manure Surplus Phosphate [ton Manure] Solid fraction Surplus Nitrogen [ton Solid fraction] Solid fraction Surplus Phosphate [ton Solid fraction] Separator Parteurization Screwpress No With chp heat Manure composition Digester Separator Manure Input Cosubstrate Input Digestate Output Solid fraction Liquid fraction Mass [ton] Volume [m3] Nitrogen (N) [kg N] Mineralised Nitrogen (Nm) [kg Nm] Phosphate (P2O5) [kg P2O5] 69

70 Tips & tricks 70

71 Tips & tricks Default values When you leave a decision cell blank, default values are used Change language Change currency Add substrates Country specific values 71

72 Language Default language for every country Language can be changed independently Select (if necessary) the language before you start, the tool cannot cope with changing the language halfway! 72

73 Currency Default currency for energy country Database and calculation is EURO! Interface in selected currency 73

74 Interface currency Micro-scale digestion calculation tool Co-funded by the Intelligent Energy Europe Programme of the European Union Version 0.9 Not for distribution! Business What is your country Netherlands Name Test Case Change your language English Adress De Marke What is your region Gelderland Select currency PLN - Polish Zloty [PLN/EUR] Exchange rate 4,153 Change subsidy rules Default exchange rate can be adapted not in use Livestock Specify number of animals and time in barn AND/OR Specify supply of manure Specify livestock Specify Type of manure Day-fresh manure Number of animals Grazing Manure Supply Costs [Species] [type of animal] [Solid or Liquid] [yes or no] [#] [days/year] [hour/day] [ton/year] [PLN/ton] Cows Dairy cows Liquid manure Yes 300 Cows Young dairy cows (calf <1 year) Liquid manure No 60 Cows Young dairy cows (yearling >1 yea Liquid manure No 60 Total - - Cofermentation Do you want cofermentation? Digester Volume 622 Specify cosubstrates Cosubstrate Costs Price indication Organic Overwrite Volume [Category] [ton/year] [PLN/ton] [PLN/ton] [yes or no] Retention time 25 ODM load 2,66 Nitrogen load 2,08 DM input 7,50 ODM input 6,59 DM Digestate 3,93 Water 0-0 ODM Digestate 2,99 Total - - Nitrogen organic origin - Share (mass) cosubstrates of total digester input The - use [%] of the offline expert feasibility Based on your farmsize you can produce pe 74 Land use to produce cosubtrates calculator - [ha] for small scale digestion Biogas potential Biogas Methane content 55%

75 Add substrates Species Species type Substrate type C1_Manure production C2_Rel_dens C3_Dry [name] [name] [solid or liquid] [ton/animal.year] [ton/m³] [Mass% Cows Dairy cows Liquid manure 26,9 1,01 Cows Dairy cows Solid manure 13,14 0,83 Cows Young dairy cows (calf <1 year) Liquid manure 5,2 1,01 Cows Young dairy cows (calf <1 year) Solid manure 13,14 1,01 Cows Young dairy cows (yearling >1 year) Liquid manure 13,2 1,01 Cows Young dairy cows (yearling >1 year) Solid manure 13,14 1,01 Bulls Bulls for meat Liquid manure 10,2 1,01 Bulls Bulls for meat Solid manure 10,2 1,01 Bulls Young bulls for meat (calf) Liquid manure 5 1,01 Pigs Mature pigs for meat (porkers) Liquid manure 1,5 1,01 Pigs Female mature pigs Liquid manure 5,8 1,01 Pigs Female mature pigs Solid manure Editable cells 2,19 0,91 Poultry Piglets aaaaaaaa16 Solid manurechoose a unique name! 0,6 0,91 Poultry Broilers Solid manure 0,011 0,5 Poultry Hens for eggs Solid manure 0,018 0,5 Other Water Liquid manure 13 1 Other Water Solid manure

76 Substrate variables C1_Manure production [ton/animal.year] C2_Rel_dens [ton/m³] C3_Dry matter [Mass%] C4_ODM [%] C5_Biogas_pot_low [m³/kg_ods] C6_Biogas_pot_med [m³/kg_ods] C7_Methane_content [vol%] C8_Carbon dioxide [vol%] C9_Retention time [days] C10_Slib [Mass%] C11_Potassium [Mass%] C12_Phosphate [Mass%] C13_Organic bound nitrogen [Mass%] C14_Mineralised nitrogen [Mass%] C15_CO2 uptake [kgco2/mwhp] 76

77 Country specific values 77

78 Questions? Berry de Jong CCS Energie-Advies +31 (0)