GLOBAL BIOMETHANE CONGRESS 2012 Brussells 9-10 october 2012

Transcription

1 GLOBAL BIOMETHANE CONGRESS 2012 Brussells 9-10 october 2012 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 1

2 DICMA (Italy) CoNISMa (Italy) Ecoil (Italy) NERI (Denmark) DTI (Denmark) CSMCRI (India) NGVAEurope (Spain) SGtS (Sweden) HU (Jordan) RTU (Latvia) AP (India) PV (Italy) Faculty of Engineering Department of Chemical Engineering Material and Environment (coordinator) National Interuniversity Consortium for Ocean Sciences National Environmental Research Institute, Aarhus University Danish Technological Institute Central Salt & Marine Chemicals Research Institute Natural Gas Vehicle Association Scandinavian Gas Treatment Service Hashemite University Riga Technical University Aquagri Process Pvt Ltd Power Ventures 2

3 Critical points to be solved Energy demand CO2 Emissions Eutrophication

4 BIOWASTE Green house gases Exhaust gases CO 2 NO X So x agro-industrial Subproduct Eutrophication agents N, P, K ALGAE 2 nd generation Biofuels Biogas Biomethane Anaerobic Digestion umidity > 70%, Photosynthesis C/N = efficiency (10% - 12%) Terrestrial Plants (3%- 5%) Biomass production: N, P, K ; Light ;CO 2 Umidity =80% C/N = 20 Low lignin

5 PROJECT OBJECTIVES 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. 5

6 WHERE THE B4B PLANT IS PLACED? 6

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8 Biogas Algae ALGAE CULTIVATION POOLS Manure Whey CO 2 N SunLight

9 GAS RECOLLECTION SYSTEM Connection to the CHEMINEE 9

10 FAN GAS RECOLLECTION AND DISTRIBUTION SCHEME WP3 Just few pictures Steam Generator room FLOW RATE BOILER 1: m 3 /h BOILER 2: m 3 /h N, P Combined gas& washed manure Mixing system 1 m m 3 1 m 3 m Toward 3 ponds 2 3 Pond 1 Pond 4 10

11 Proximate composition of different seaweeds Results obtained by Indian Partners CSMCRI & AP S.No Species Carbohydrate (% DW) Protein (% DW) Lipid (% DW) Moisture ( %) Chlorophyta 19. Ulva 56.07±2.68 b 18.57± ± ±0.7 Species Daily Growth Rate (%) U. lactuca 27.6 ± 2.31 Ulva lactuca 11

12 Protoplasts yield and regeneration rate Isolated protoplasts Calcofluor stained protoplasts Species Protoplasts yield (cells/g fresh wt.) Protoplasts Regeneration Rate (%) U. lactuca 4.0 ± ±

13 Results from pilot scale plant in Denmark Blowing Flue gas = blowing CO 2 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 13

14 Ulva species test on site by Conisma & Ecoil Autoctonous Ulva seaweeds selected in Augusta harbour With hens manure Without manure 14

15 ONCE THAT: 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 Time to test results in a pre-industrial scale plant 15

16 FLOATING PONDS ASSEMBLY 16

17 HARVESTING TECHNOLOGY Manual harvest usually adopted in India and Africa also to keep intact the organoleptic properties B4B R&D activities: RoboHARV 17

18 Equipped with two floater Collects algae to the corner Easily removed by pumps NEW DESIGN 18

19 PLANT DESCRIPTION Total volume: 160 m 3 Footprint approx. 120 m 2 The purpose of this plant is to digest about kg/day of raw poultry manure mixed with algal biomass and to produce 1 kw ep per each Kilogram of raw manure, recovering combustion CO 2 in algae pond. 19

20 Hydrolysis stage N 2 Tanks : m 2,50 ø m 6,20 h CSTR Cohibented Feed rate From 5 to 24 m 3 /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 20

21 Methanation stage N 1 basin: m 6,0x2,4x4,0 h Cohibented Archimedes RBC Volume: 22 m 3 Active surface: m 2 Feed rate From 5 to 24 m 3 /day Dissolved solids concentration from 5 to 20 % Temperature range: from 30 C to 55 C Expected biogas production: from 200 to 350 m 3 /day HRT adjustable 21

22 Wastewater treatment N 1 basin: m 3,0 x 2,4 x 2,8 h Archimedes RBC Volume: 11 m 3 Active surface: m 2 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) 22

23 PLANT PONDS Average a 600 cow farm produce: HOMOGENIZATION TREATMENT PLANT PREPARATION HIDROLISYS CHP METHANATION 23

24 FROM BIOGAS TO BIOMETHANE CRIOGENIC UPGRADING TO LBG 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 CH 4 LBG reduces the NO x emission to almost zero 24

25 SMALL SCALE PLANT FIND A FINAL USER FOR LBG B4B PROJECT FIRST HYPOTESIS UPGRADING UNIT DATA: 10 Nm 3 /h for LBG production Consumption kw To high energy request for a m 3 /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 m 3 /h 25

26 SMALL SCALE PLANT FIND A FINAL USER (CBG) B4B PROJECT SECOND HYPOTESIS UPGRADING UNIT DATA: 10 [Nm 3 /h] unit for the cryogenic production of CBG Consumption [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 agroindustrial field PROBABLY - Biomethane requires incentives to make profitable its production. 26

27 CBG and dual fuels a possible solution for agro-industry 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 27

28 CBG and Diesel Dual Fuel 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 28

29 B4B Life Cycle Impact Assessment: Fossil fuel consumption Reduction of fuel consumption up to 34% All scenarios absolve the same function Consumption unit [tep]

30 Life Cycle Impact Assessment: Green house gases Reduction up to 35% - 75% All scenarios absolve the same function Emissions unit [ton CO2 equivalent]

31 Biogas v/s Biomethane? B4B case study FEED IN TARIFF: FOR BIOGAS PLANTS SINCE THE 1 st 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 31

32 CHP B4B case study 45 kwe CHP (ELECTRICITY PRODUCTION) 25 m3/h of Biogas (65% CH4) 45 kw e /h * 8000 h/y = kwh 360 MWh * 266 /MWh= /year Maintainance /year : transports, etc No interesting Payback Time >8 year B4B PROJECT IS A RTD PROTOTYPE AND IS NOT ALLOWED TO REQUESTS ANY INCENTIVES. 32

33 CHP 2XB4B case study 100 kwe CHP (ELECTRICITY PRODUCTION) 50 m3/h of Biogas (65% CH4) 100 kw e /h * 8000 h/y = kwh 800 MWh * 266 /MWh= /year Theoretical cost Net profit /y No transport costs (inside the farm) Electricity costs 0,15 /kwh * 8 kwh/h * 8000 h/y= /year maintenance cost 9% (very conservative) 9% financial interest PBT < kw biogas plant works 33

34 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 /year) PBT >10 years Taxes for transportation use (around 4,47 / kg)= 1032 /year Electricity costs 0,15 /kwh * 22 kwh/h * 8000 h/y= /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 Electricity costs 0,15 /kwh * 15 kwh/h * 8000 h/y= /year Maintainance costs (pipe rent ; electricity /year ) Upgrading & Compression consumption 8-15 kw AD Plant section average consumption 6 kw 34

35 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: Net profit /year Maintainance 34% (El. 26%) PBT >10 years (9% fin. Interest) Taxes for transport use (around 4,47 / kg)= 871 /year Electricity costs 0,15 /kwh * 42 kwh/h * 8000 h/y= /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 Electricity costs 0,15 /kwh * 26 kwh/h * 8000 h/y= /year Consumption of 32 kw for upgrading & Compression AD plant section average Consumption 10 kw 35

36 Plant cost: Plant cost: Biogas v/s Biomethane? 2 X B4B (on going) 50 m3/h kwe CHP (ELECTRICITY PRODUCTION) 800 MWh * 266 /MWh= /year Maintainance 12,5% (El /year 4,5%) Net Profit: 186,176 /year PBT <5 years Incentive equivalent 0,425 /m3 (1 Sm 3 > 1,6 kwh e ) 50 m3/h (CBG PRODUCTION + REFUELING STATION ) 8000 h/year * 24,5 /h = 196,000 /year Maintainance 34% (El /year 26%)) Net Profit: 129,360 /year - PBT >10 years Min. feed in tariff 0,30 /kg *195 ton/year = 56,816 /year (GRID INJECTION) - Low pressure 8000 h/year * 10,53 /h = 84,280 /year Maintainance 45% (El /year 37%) Net Profit: /y PBT >10 years Min. feed in tariff 0,76 /kg * 195 ton/year = /year 36

37 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 37

38 THANKS! FOR: INFORMATION- DETAILS SUGGESTION FURTHER REQUESTS PROPOSAL NEW PROJECT ETC ETC PLEASE CONTACT