Making an Agricultural Waste-to-Energy Facility Work on a South Carolina Swine Farm
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1 Making an Agricultural Waste-to-Energy Facility Work on a South Carolina Swine Farm BioPro Expo & Marketplace / Atlanta, GA / March 14-16, 2011
2 Burrows Hall Bioenergy Project Agenda The Project The Challenges Waste to Energy: Basics, Anaerobic Digestion, & Biogas Practical Considerations Our System Lessons Learned
3 Burrows Hall Bioenergy Project Funded by a grant from the South Carolina Department of Agriculture and administered by the South Carolina Energy Office. The Partners: Farmer Santee Cooper (South Carolina's state owned electric and water utility) SCIES (South Carolina Institute for Energy Studies) System Builder
4 The Challenges Over 2,000 anaerobic digester (AD) systems on farms in Europe in Germany 2 Advanced technologies in Europe 151 digester systems at commercial livestock facilities in US 3 None in SC None successful in NC & GA (despite a NC mandate that 0.07 percent of electric sales come from swine waste by 2012.) Relatively Small generation potential (100s of kw vs. MWs) Low cost of electricity in the Southeast 1 Preusser, Steffen Biogas Polities and Technologies in Germany. Agricultural Waste to Energy Workshop. Abbotsford, British Columbia, July BBI International, Lakewood, Colorado 3 AgStar, 2010
5 Waste-to-Energy Agricultural Waste manure Agricultural Waste crop residue Food Processing rendering, preparation, fruit & vegetable Municipal Wastewater Industrial Waste Municipal Solid Waste (Landfill gas) Biomass other Energy Crops
6 Energy Conversion Options Direct Combustion Gasification Anaerobic Digestion
7 Anaerobic Digestion anaerobic decomposition: decomposition of organic matter by bacteria in the absence of oxygen organic molecules: carbohydrates proteins amino acids lipids C, H, N, O, S, P anaerobic bacteria no O 2 CH 4, CO 2 NH 3, NH 4+, H 2 S, HPO 4 2, H 2 PO 4 multi step process
8 Biogas Burn biogas as source of heat. Clean biogas for sale as natural gas. Burn in an engine for mechanical/electrical energy. internal combustion engine or turbine 1 CHP = Combined Heat & Power Burn ( flare ) to convert CH 4 to CO or Fuel Cell 2 CH 4 21x more potent than CO 2 as GHG
9 Anaerobic Digestion Total Solids (T.S.) Volatile Solids (V.S.) COD organic load Hydraulic Retention Time (HRT) assumptions: 50% conversion of C to CH 4 gas turbine: 25% efficiency gas engine: 30 40% efficiency AD turbine: 1,285 BTU/lb VS AD engine: 2,056 BTU/lb VS
10 Example Energy Estimate example: Swine TS = 6.34 lb/d/1000# (1000# = 1 A.U.) VS = 5.40 lb/d/1000# 10,000 animals average animal wt = 150 lb 5.40 lb/d/1000# x 10,000 animals x 150 lb/animal x 1 A.U./1000# = 8,100 lb VS/day 8,100 lb VS/day x kw h/lb VS 203 kw
11 Agricultural Waste: Practical Considerations CAFO = Concentrated Animal Feeding Operation Free range Type of animal Manure handling, management, water management % solids Bedding materials
12
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14 AD Systems: Practical Considerations Batch Continuous Complete Mix Plug Flow Fixed Film Tanks Lagoons Temperatures: < 30ºC (psychrophilic) (<86ºF) 30 40ºC (mesophilic) (86 104ºF) 40 55ºC (thermophilic) ( ºF)
15 Anaerobic Digester New lagoon Lined, covered, insulated Mixed Heated to 95 o F (mesophilic) Gas collection Rain water collection > 20 year life
16 Water Recirculation Land Application Excess Liquids Effluent Storage Lagoon Effluent Excess Biogas Biogas Flare Electric Grid Biogas Biogas Swine Houses Waste Anaerobic Digester H 2 S Scrubber CHP Unit Electricity Digester Heating Heat
17
18 Photo: Environmental Fabrics, Inc. Digester Construction
19 Photo: Environmental Fabrics, Inc. Digester Construction
20 Photo: Environmental Fabrics, Inc. Digester Construction
21 Example Digester Construction
22 Power Generation Piston Engine MAN Nutzfahrzeuge AG Vogelweiherstr Nuremberg
23 Economics Sale of Electricity Carbon Credits Renewable Energy Certificates Renewable Energy Production Incentives Renewable Energy Production Tax Credits Sale of Byproducts? Also consider behind the meter options.
24 Lessons Learned Chose simple, proven technologies Reciprocating engine vs. turbine (+ gas conditioning) vs. fuel cell Sale of power Agreements Permits Co digestion could increase production.
25 Sale of Power Good PPA a necessity! Example: AD system in another state Example: a co op s position on small renewables Example: a large utility s position on small renewables No net metering, no RPS in South Carolina.
26 Business Agreements Power Purchase Agreement (PPA) Waste Stream/Lease Agreement Interconnection Agreement
27 Permits SC DHEC Agricultural Permit SC DHEC Air Quality Permit County Building Permits No increase in hog operation No change in water discharge
28 Burrows Hall Bioenergy Project South Carolina s first Agricultural Waste to Energy Project on line June kw
29 South Carolina s s First Agricultural Waste-to to-energy Project (864) Craig Campbell ccampbell@clemson.edu
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