BINDER. Biogas Conference Manila, 12. April 2016

Transcription

1 Biogas Conference Manila, 12. April 216

2 Biogas Conference Manila, 12. April 216 Introduction Binder Why Monitoring on Biogas Plants? Technologies Service and Maintenance Conclusion 2

3 Binder Group AG Finance Holding Binder Engineering GmbH Sales & Service Companies in DE / F / CH / NL / B / China, Singapore, Malaysia BINDER GmbH Manufacturing Company for Gas Flowmeter, Gas Analyzer and Control Systems with following products: COMBIMASS / VACOMASS / CAMASS INSTRUM AG Manufacturing Company for Stainless Steel Pressure Regulators and Valves BETA B.V. Manufacturing Company for Pressure and Temperature Switches

4 Introduction Binder s core business is Gas Flow Metering and Control. Aeration Control System & Digester Gas Flow Metering & Analysis 4

5 SEAP Set-Up S. Korea Status Binder Group Binder Sub/Rep.Office Binder Distributor/Partner Service Center 5

6 Why is it necessary to monitor Biogas Plants? 6

7 Parameters to be monitored in a biogas plant Gas production and composition Process parameters in the digester (ph, temperature,..) 7

8 CH4 Methane Concentration Measurement This is the product that we want. It is therefore essential that your plant maximises the percentage of CH4 produced. It is a good practice to document and record the quantity, quality and composition of the Biogas being generated. A clear indication of the yield of your plant per tonne of feedstock. 8

9 O2 Oxygen Concentration Measurement - this is a critical process indicator. You have to ensure that we are not producing an inefficient or explosive mixture of Methane and Oxygen gases. Increasing Oxygen levels could indicate performance issues leading to a decrease in microbial activity (poisoning) in the anaerobic digester or inward leaks into the system, both affecting productivity of the plant. 9

10 H2S Hydrogen Sulphide Concentration Measurement - this is a highly toxic and corrosive gas. It is essential its concentration be monitored. High levels of H2S must be prevented as it is corrosive to engines and can condense and form Sulphuric Acid within the process resulting in large operational and maintenance costs. Most engines typically require less than 2ppm H2S, but as the concentration can often rise well above this it is important to know when this is occurring so appropriate steps can be taken. Feeding of gas into a network grid has more stringent requirements 1

11 CO2 Carbon Dioxide Measurement - In a similar way to the measurement of the Oxygen levels present, the Carbon Dioxide composition is a good indicator of the performance of the plant, ensuring that the anaerobic digester is operating efficiently. Rising CO2 levels would indicate a drop in quality of the fuel being supplied to the Combined Heat and Power (CHP) generator. 11

12 .. It is highly advisable to analyze the composition of the biogas in the raw state and before the CHP regarding CH 4, H 2 S and O 2. Thus, changes in the biogas and the cleaning measures function can be monitored. The analysis must be made regularly at least daily. In case of unevenly distributed feeding and expected fluctuations in the biogas composition, the analysis frequency needs to be adapted. It is advisable to use gas analyzer with set-limits and alarm and opportunity to integrate them into an existing plant control. Methane sensors must be pressure and temperature compensated; hydrogen sulphide sensors also need to be sufficiently resistant with peak concentrations. Regular calibration according to the manufacturer's instructions are generally to follow... " 12

13 Why is process monitoring necessary? Supervision of individual components, e.g. H 2 S scrubber Protection of sensitive equipment, e.g. CHP-engine Preventive alarm settings to react timely on process fluctuations Improve feeding cycles and reduce raw material usage Comply to legal requirements, e.g. evidence of biogas production volumes and gas-quality Increase of safety, efficiency and profitability 13

14 Technologies for Flow & Analyze of Biogas 14

15 Typical measurement locations Gas to grid Further gastreatment, liquefying, Discharge gas (1) (2) Production User Discharge/Upgrading (3) (4) (5) (6) (1) Substrate pre-treatment (2) Feeding unit (3) Hygienization (4) Main Digester (5) Secondary digester (6) Fermentation residue (7) Gas storage/h 2 S scrubber (8) Use for burners Drying, Pelleting, Agriculture (9) CHP-unit (1) Satellite CHP-unit (11) Flare (12) Gas-upgrading 15

16 Gas qualities on the different measuring points Gas Production: At the digester, after gas-cooler, after gas-storage, in front of the H 2 S-scrubber/filter dirty, wet, corrosive, low pressure (-3 +3 mbar), low velocities (,5 3m/s) CH Vol.-%, CO Vol.-%, O 2-1 Vol.-%, N 2-5 Vol.-%, H 2 S up to 1 ppm, H 2 -vapour up to 15 Vol.-% (thermophilic) Gas-Use: After H 2 S-scrubber/filter, in front of the CHP-unit, in front of the flare, in front of the burner/boiler Less dirty, partly dry, still corrosive, higher pressure (4 8 mbar), higher velocity (8 15 m/s) CH Vol.-%, CO Vol.-%, O 2-1 Vol.-%, N 2-5 Vol.-%, H 2 S < 1 ppm, H 2 -vapour < 1 Vol.-% Upgrade and discharge: After bio-methanization plant, in front of the feed-in point to the gas grid Clean, dry, high pressure (bar ranges), high velocity CH Vol.-%, CO Vol.-%, H 2 S < 2 ppm 16

17 Definition Standard-Cubic-Meter Measuring volumetric flow compensation Standard Volume V Gas Mass m Volume Pressure Temperature Biogas: + Humidity + Gas-Composition p & T compensation necessary for: Orifice plates DP Vortex flow meter Turbine meters/ mechanical counters Ultrasonic flow meter Pitot tubes... 17

18 Overview (according ATV-DWA M 264) Orifice plate Mechanical counter Thermal meter Vortex meter Ultrasonic meter Measured value Compensation to standard conditions volumetric flow pressure, temperature, humidity volumetric flow pressure, temperature, humidity mass flow at standard temperature and pressure humitidy volumetric flow pressure, temperature, humidity volumetric flow pressure, temperature, humidity Maintenance efforts Significantly high efforts Significantly high efforts Low efforts Low efforts Low efforts Typical accuracies ±1 % of measured value ±2 % of measured value ±1 % to ±2,5 % of measured value + const. part ±1 % of measured value + const. part Up to ±1,5 % of measured value 18

19 COMBIMASS - thermal gas flow measurement 19

20 COMBIMASS Thermal dispersion mass flow measurement flow heated sensor reference sensor no flow Temperature: Sensors measure resistance (by use of Pt1 sensors) second sensor provides as reference Principle: Dispersed heat provides as reference for the amount of gas-molecules passing by direct mass-flow measurement Advantages: Unaffected by pressure and temperature changes, very low pressure drop, precise even at low flow rates, reference sensor can be used to provide the gas temperature. Challenge: A CH 4 -molecule disperse a different amount of heat than a CO 2 -molecule etc. Also water damp molecules disperse heat. 2

21 Advantages COMBIMASS Thermal Dispersion Flowmeters insertion type for easy installation designed for minimal pressure loss robust, corrosion resistant require minimal maintenance have no mechanical moving parts measure directly the normal volumetric or the gas mass flow unaffected by pressure and temperature fluctuations with a turndown ratio up to 1 : 1 an accuracy up to 1% operating pressures up to 63 bar 21

22 Typical tasks for measurements Measurement of Gas Quality in different application (Anerobic digestion, Dry fermentation, Syngas) - Adjust engine parameters after changing CH4 concentrations - Monitor process performance (check digester output) - Supervise and operate H2S scrubber - Control input / feeding cycles 22

23 Gas-Analyzing-Methods/Principles Technology CH 4 CO 2 O 2 NH 3 H 2 H 2 O H 2 S Infrared Absorption Electrochemical Heat conductivity Flame ionization Photo ionization Gas chromatography Resistance sensors Laboratory Field Capacitive sensors 8 not suitable.. 1-fits very well H 2 S-cells musn t be overloaded! 23

24 BINDER Gas analysis 24

25 Analyzer station COMBIMASS hybrid The New flexible analyzer system: flexibility in cabinet sizes & material flexibility in size of graphic display flexibility in gas cells flexible for indoors/outdoors flexible in sampling frequency and sequence (continuously/ frequently) Easy assembly and maintenance Modular System for specific customer s requirement 25

26 Features of the hybrid system Analyzer cabinet ( min.4x4 plastics, 24 VDC or 7x4 SS) for wallmounting installation/ free-standing in a safe area and non-corrosive ambient, +5 to + 4 C ambient temperature (indoors), LEL-monitored by separate means, with flexible configuration and sampling sequences. For outdoor installation a bigger cabinet with heating/ air conditioning is used or a second cabinet is built around. Gas analyzer cabinet can be with GA-m or GA-e with an additional H 2 -HC-module or CO-HC-module. Gas analyzer can be with various modules. Gas analyzer can be with a gas cooler for continuously sampling and analyzing of CH 4 -IR and O 2 -PM. Gas analyzer can be with two H 2 S-EC-modules only. Gas analyzer can have auto-calibration. Gas analyzer can have a big display 7 with graphs. Gas analyzer can send data via modem or Ethernet to 26

27 Add-on biogas flow sensor for all analyzer stations Calibration range:,3 25 m/s (calibration acc. application) Sensor length: 2 45 mm Sensor diameter: 12 mm only Composition of gas: 65% CH 4 / 35% CO 2 (standard) Option display: yes, but not recommended Option Ex-proof: yes, zone 1 Humidity correction: yes Flow correction: yes, in the GA-s (using actual gas composition) Flow direction and installation details will taken into consideration at calibration. 27

28 Service and Maintenance 28

29 Maintenance is work that is carried out to preserve an asset, in order to enable its continued use and function above a minimum acceptable level of performance over its design service life, without unforeseen renewal or major repair activities. Support the business continuity in the most efficient manner. Ensuring the asset is design and operated correctly to it intended purpose Prolonging the assets life Maximising equipment capability from the original design Improving the asset performance Ensuring quality of production/service delivered in timely manner Responsible care in Safety health and environment Compliance to regulatory requirements and accreditation needs Promoting and maintaining Corporate image/status 29

30 Service and Repair What is service? Inspection (inward inspection) Service work / Maintenance replacement of cells, battery, gas pump, keypad and other mechanical parts, leakage test and sealing of the instrument, further tests and checks, calibration, set new/other calibration points than standard ones, put new software on Outward inspection What is repair? Remedy damage related to Electronics Remedy damage related to IR-bench and EC cells 3

31 Recommendation Binder * Maintenance Schedules portable use every 12 months O2-cell every 24 months battery and other electrochemical cells every 3 years gas pump stationary use every 12 months all electro-chemical cells every 24 months battery every 3 years gas pump * may differ for other manufacturers 31

32 Maintenance Made Easier As Gas Analysers are essential for monitoring the process in your Biogas Plant, it is imperative that you must maintain this equipment. Any downtime will put your plant at risks. Eliminate the tedious task of exchanging cells by using modular cells. (No need skill technicians to exchange a Hybrid Module) Providing optional auto calibration to dispense with the need for on-site or off-site calibration Ethernet/Internet remote control, trouble-shoots and diagnostic assessment Calibration and maintenance with local service back-up and on site recalibration possibility 32

33 Conclusions 33

34 Conclusion Strong local partner State of the art technology Maintenance made easy stable, safe and profitable operations 34

35 We are happy to receive your feedback, questions and remarks. Jan Talkenberger Manager International Sales Binder GmbH Buchbrunnenweg Ulm, Germany Alex Hwong Sales Director South East Asia Pacific B-3A-25 Blk Bougainvillea, 1 Boulevard, Lebuhraya Sprint 474 Petaling Jaya, Selangor, Malaysia 35