German Indonesia Forum on Innovative Technology to Tap Indonesia s Bioenergy Potential. Efficiency and Profitability in Biogas Plants

Transcription

1 German Indonesia Forum on Innovative Technology to Tap Indonesia s Bioenergy Potential Efficiency and Profitability in Biogas Plants Jan Talkenberger 1

2 Binder Group AG Finance Holding Binder Engineering GmbH Sales & Service Companies in DE / F / CH / NL / B / Singapore, China 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

3 BINDER Gas flow measurement 3

4 BINDER Gas analysis 4

5 German Indonesia Forum on Innovative Technology to Tap Indonesia s Bioenergy Potential November 17th, 214, Intercontinental Midplaza, Jakarta What parameters should be measured in biogas plants? Flow metering of wet and dirty biogas is a challenge different technologies influence of humidity and changing gas composition overview of available technologies Analysis of biogas with field instruments portable vs. stationary instruments overview of available technologies limits of use Combination of gas analysis and flow metering for improved accuracy Use of precise process information for control of feeding cycles - introduction Plant monitoring introduction 5

6 Chapter 1: What parameters should be measured in 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 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 8

9 .. 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... " 9

10 Chapter 2: Flow metering of wet and dirty biogas is a challenge Different technologies Influence of humidity and changing gas composition Overview of available technologies 1

11 Definition Standard-Cubic-Meter Volume vs. Mass volumetric m 3 vs. standardized m 3 p 1 / T 1 p 2 / T 2 Mass Flow is independent from any pressure and/or temperature change! 11

12 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... 12

13 Definition Standard-Cubic-Meter DIN 1343: Standard-Cubic-Meter is defined at following conditions: C (+273 K) Standard-temperature 1,1325 bar Standard-pressure % relative Humidity DIN 1343:199-1 Biogas is a wet (humid) gas, the humidity portion depends on the location of the measurement point and the gas temperature. All measuring methods measure the humidity portion as well. It must be compensated to comply to standard conditions. 13

14 Gas to grid Further gas-treatment, liquefying, Typical measurement locations 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 14

15 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 15

16 Overview on different measurement principles 16

17 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 17

18 Influence Factors to Measurement: Summary Measurement Principle: Pressure-Compensation Temperature-Compensation Humidity-Compensation Installation: Straight Inlet- and Outlet piping flow profile Pulsations Calibration Manipulation safety 18

19 Conclusions Thermal Mass Flow technology seems to be best suited for biogas applications: can measure low speed at low pressure rugged design fits very well to tough conditions only one correction (humidity) necessary low maintenance (normally only cleaning once a year) sufficient accuracy and repeatability for a field instrument reasonable cost easy installation 19

20 Chapter 3: Analysis of biogas with field instruments Portable vs. stationary instruments Overview of available technologies Limits of use 2

21 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! 21

22 Gas Analyzer - Field Instruments portable vs. stationary 22

23 Portable and stationary units Portable units flexible use Sharing between operators Service Companies Stationary Implement in plant control systems Frequent measurements 23

24 Main advantages of a portable unit at different places applicable, data can be stored measuring point-specific * simple operation rugged technology, low-maintenance simple maintenance on site recalibration integration of other measurements like gas flow, gas temperature & pressure possible * correction of flow signal by actual gas composition integrated * measuring data recording, PC evaluation ATEX certified * * not from all suppliers available 24

25 Main advantages of a stationary unit realizes programmed continuous sampling cycles suited for safety monitoring (automatized solution) contains high performance measuring gas pump and highquality solenoid valves various data storage and transmission options continuous correction of flow signals with gas-composition changes * alarm detection & transmission for leakages, over/falling below of set points * climatized cabinet for outdoor installation possible (incl. air cooling/heating and LEL-control of the cabinet) gas feed back into the process pipe possible * * not from all suppliers available 25

26 Chapter 4: Combination of gas analysis and flow metering for improved accuracy 26

27 Water contents in g /m³ BINDER Humidity Correction in Analyzer Cabinet At some installation positions in the plant the gas is waterdamp saturated. Based on temperature of the biogas and assuming a relative humidity of 1%, the water contents can be calculated by Magnus equation. Measurement points must be at fully saturated gas, e.g. directly after digester, temperature mustn't be increased due to blowers, direct sun light etc. Option: Fixed value can be set, if lowest temperature (max. absolute water content) before the flow meter is known and fix Temperature in C Water contents in Vol.-% 27

28 Humidity Correction in Analyzer Cabinet If gas is not waterdamp saturated correction must be done based on relative humidity / dewpoint determination. A special sensor measures the relative humidity respectively the dew point (1% saturated) and so the water contents can be determined. The probe is sensitive against H 2 S (sensor poison, will get damaged), therefore it can be used only after the filter at very low H 2 S-concentrations. Comparatively high cost for the sensor. 28

29 Biogas flow correction by changing CH 4 contents Methane concentration in the biogas is changing time-depending, load-depending, feed depending, process depending, Based on actual CH 4 -concentration and gas velocity a correction factor is calculated and used for flow correction. Example: Correction module COMBIMASS if an analyzer station is already at site 29

30 Chapter 5: Use of precise process information for control of feeding cycles - introduction 3

31 Economical factors for plant operation Monitoring and control of all factors which could influence the process Highly technologized processes require highly educated operating staff (training) Efficiency of biological process Quality and nutritional value of the fermenting rest (new valuable material) Life time of technical equipment and resources 31

32 State of the art - so far Filling of the digester in fixed time sequences Variations in fermentation processes Operation of flares for surplus biogas (=waste of gas) CHP-unit don t run at full load if not enough gas is stored Low volumetric loading Time in-dependent control of electrical consumer Distribution of waste heat without control 32

33 How process improvement can be achieved Load-Depending filling of the digester (according to actual demand of the consumer filling level of gas storage tank) Damping of fluctuations in the biological process Increase of volumetric load Time-depending control of the consumer Control of surplus heat use and distribution Common Problem: Available information about the process are insufficient, because gas flow is not measured and gas composition not analyzed. If information available, data are often not used for process control. 33

34 Chapter 6: Plant monitoring Introduction 34

35 Plant Monitoring Manual Operation Automatic Operation Visualization Automation Control Level Instrumentation Field Level 35

36 Plant Monitoring Mandatory Needs: Instrumentation in Field Level Data Transfer: Field Control Level Actuators Optionals: Remote Access (internet, GSM, radio, ) Alarms, actions via remote access tools (tablet, cell-phone) 36

37 Questions / Remarks? We are happy to receive your feedback, questions and remarks. Jan Talkenberger Manager International Sales jan.talkenberger@bindergroup.info Binder GmbH Buchbrunnenweg Ulm, Germany Alex Hwong Sales Director South East Asia Pacific alex.hwong@bindergroup.info No B-3A-25 Block Bougainvillea 1 Boulevard, Lebuhraya Sprint PJU6A, 474 Petaling Jaya, Selangor, Malaysia 37