The Uilenkraal Bio-gas Power Generation Plant Dr. Andrew Taylor Cape Advanced Engineering (Pty) Ltd andrewtaylor@cae.co.za 4 October 2015
the South African reality typical Eskom winter profile - 2015 peak from 4 pm to 9 pm no sun for solar wind? no sun peak sun no sun 17 hours of peaking capacity is required CAPE ADVANCED ENGINEERING (PTY) LTD 2
Uilenkraal project investment motivation the 2003 RE White Paper Supply shortage predicted from 2006 LOAD SHEDDING an Energy Policy is a Constitutional requirement! the stated problems problems not emphasised coal dependence - water issues? greenhouse gasses - unemployment? energy security - food cost & food security? acknowledged local entrepreneurship & innovativeness 10-year target 10 000 GW.hr generated by 2013 and 1.7 GW operational in 2013. early win targets included bio-mass combustion (sugar and wood) and solar water heating bio-mass was prominent (combustion prominent?) technology development was encouraged! CAPE ADVANCED ENGINEERING (PTY) LTD 3
then the NERSA REFIT programme 2nd quarter 2009 REFIT I announced 4th quarter 2009 REFIT II announced incl. bio-gas 31 December 2009 REFIT Gazetted but without any provision for bio-gas why? 1st quarter of 2011 REFIT disbanded why? August 2011 REIPPP initiated no provision for bio-gas why? 5 November 2012 Financial closure on 1st round of wind and solar projects, then rounds 2, 3 and 4 still no provision for bio-gas - why? then foreign intervention by the UN and GIZ etc. CAPE ADVANCED ENGINEERING (PTY) LTD 4
cost comparison with REIPPP Round 1 REIPPP round 1 involved 28 projects 1,416 MW for a total investment of US$ 5.97 billion 18 PV technology installed capacity of 632 MW 2 CSP technology installed capacity of 150 MW 8 wind technology installed capacity of 634 MW average cost of each project = R 2.763 billion per project average cost of installed capacity = R 55 million per MW installed CAPE ADVANCED ENGINEERING (PTY) LTD 5
cost comparison with REIPPP Round 1 average cost = R 55 million per MW capacity installed if solar PV projects yield of 20% of installed capacity, and if wind projects yield of 30% then average yield of round 1 ~ 24.5% then average actual cost of solar & wind = R223 million per MW generated (the true cost of effective capacity ) CAPE ADVANCED ENGINEERING (PTY) LTD 6
bio-gas power in Germany same power output as new SA coal plants (when running at full capacity) CAPE ADVANCED ENGINEERING (PTY) LTD 7
renewable energy in Germany bio-mass generates more than wind and solar combined CAPE ADVANCED ENGINEERING (PTY) LTD 8
bio-gas in SA in 2015 projects still denied access to the national grid REIPPP? Durban landfill project highly successful Johannnesburg Water bio-gas from waste water City of Windhoek bio-gas from waste water (CAE) CAE Uilenkraal project in Darling technical success @ <50% utilisation (project by CAE) proven capital cost in South Africa < R20 million per MW for landfill projects R1.35 / kw.hr < R30 million per MW for bio-gas projects R1.65 / kw.hr far cheaper than wind & solar & generate at peak times CAPE ADVANCED ENGINEERING (PTY) LTD 9
the Uilenkraal dairy farm a large scale total mixed ration (TMR) dairy 1500 Lactating cows in milk high roof open barns (180m) free stall animal accommodation commercial animal feed mill CAPE ADVANCED ENGINEERING (PTY) LTD 10
without grid access, power off-take is critical the commercial animal feed mill peak demand 750 kva CAPE ADVANCED ENGINEERING (PTY) LTD 11
local technology and design Hybrid, mixed and heated plug flow bio-digester Locally built bio-gas engines and CHP units Developed and Manufactured in South Africa CAPE ADVANCED ENGINEERING (PTY) LTD 12
bio-digester construction local materials > 7000 ton capacity 1% to 14% solids 20 to 40 day retention time Sequential plug-flow process
the bio-gas & fertiliser plant
Scraped manure collection Bio-Gas Generator (CHP) Electricity Out X Manure & waste water mixing Heat to biodigester Anaerobic bio-digester Biogas to generator Process heat out for food processing Biogas to Flare Flare Cattle bedding or bio-fertiliser Manure & waste water slurry in Solids separator Bio-fertiliser out Liquid bio-fertiliser storage for land application Solids Liquid
2 x 250 kva bio-gas CHP generators Developed and Manufactured in South Africa
bio-gas plant generators 22 litre V12
bio-gas plant electrical systems 1 MVA Developed and Manufactured in South Africa
Power [kw] Average load profile - Jan and Feb 2015 NB: min. set to 5 kw, peak hourly demand = 406 kw (briefly 455 kw) 400 350 Uilenkraal Bio-Gas January and February V12007 V12008 Eskom Bio-Gas TOTAL 300 250 200 150 100 50 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Time of Day CAPE ADVANCED ENGINEERING (PTY) LTD 19
74% 98% CAPE ADVANCED ENGINEERING (PTY) LTD 20
bio-fertiliser solid & liquid
Thank you for your interest Dr. Andrew Taylor Cape Advanced Engineering (Pty) Ltd andrewtaylor@cae.co.za 4 October 2015