biogas asia pacific forum 2015
TRANSCRIPT
Biogas Asia Pacific Forum 2015
Case Study : Key elements in start-up and optimisation of Biogas Capture Plant towards achieving desired KPIs
Yusriady bin Che Saad 28 – 29 April 2015, Sunway Pyramid Convention Centre, Kuala Lumpur
KONZEN CLEAN ENERGY SDN BHD
OBJECTIVES
Objectives
• To ensure the plant continuously delivered the desired Biogas production output base on its performances.
• To highlight the important of the plant performances monitoring management towards optimization of the Biogas captured.
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INTRODUCTION
Introduction
KONZEN® Clean Energy • A BioNexus Status company focusing in high organic
loading wastewater treatment such as POME • Technology developed through a series of R&D and
collaboration with university • KONZEN® GROUP has been providing total solution
for industrial water and wastewater engineering > 20 years. 3 main operating divisions: • Konzen SE Asia (KL, Penang and Kuching) • Konzen China (Tianjin and Shanghai) • Konzen Clean Energy Sdn Bhd, KCE
5
Introduction
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• Provides biogas system end-to-end turnkey services.
Introduction
7
Introduction Our Technology
• The technology developed by KONZEN® is a closed anaerobic digester tank of Continuous Stirred Tank Reactor (CSTR) type under mesophilic condition.
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Key features: • CSTR of Biogas-POME vertical mixing. • 10 days Hydraulic Retention Time • No moving parts inside digester • Heat recovered for optimum operating
temperature • sludge recycled to maintain the pH
and MLSS in the tank
The Project
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• The anaerobic digester plant is designed and built with required instrumentation and detailed programming in order to enable effective plant management and consequently maintaining consistent process deliverables.
• The Programmable Logic Control (PLC) and Supervisory Control and Data Acquisition (SCADA) system have been incorporated into the plant operation.
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• The project is divided into two phases; • 1st phase is for methane capture and flaring as the new
mill goes into production,
• 2nd phase is planned for biogas power generation when the mill reaches its full production capacity.
• The remoteness of this site makes this project extremely challenging to execute Careful planning for material selection, construction methodology and logistics was crucial.
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• Anaerobic process conducted in tank digesters would be the most suitable system for the anaerobic treatment of POME for it enables better system control and consistency.
• The key strategies to manage an anaerobic digestion system:
1. Detailing out the anaerobic operation system 2. Installing a comprehensive anaerobic process
management control system 3. Administration and process monitoring in practice
• Optimization of the operational conditions can only be executed on a well-controlled and well-monitored anaerobic system.
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1. DETAILING OUT THE ANAEROBIC OPERATING
SYSTEM
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• The main four systems
• Sectioning the plant into few systems • ease plant control implementation
• enable efficient plant troubleshooting procedures
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1. Pre- treatment system
2. Anaerobic digestion system
3. Biogas handling system
4. Post- treatment system
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Incoming raw effluent
Pre-treatment system
Anaerobic digestion system
Biogas handling system
Biogas utilization
Post-treatment
system
Biogas recycle
Supernatant discharge to aerobic treatment
Sludge
Sludge recycle
Sludge discharge to sludge collection pond
2. INSTALLING A COMPREHENSIVE
ANAEROBIC PROCESS MANAGEMENT CONTROL
SYSTEM
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• The anaerobic digester plant is designed and built with required instrumentation and detailed programming in order to enable effective plant management and consequently maintaining consistent process deliverables.
• The Programmable Logic Control (PLC) and Supervisory Control and Data Acquisition (SCADA) system have been incorporated into the plant operation.
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• Benefits of an anaerobic treatment plant with process control and monitoring management:
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Consistent anaerobic treatment process
Orderly bookkeeping of input and output
Enable maximum utilization of biogas
Reduce plant downtime
Improve general working environment
Easy and safe operation
• Parameter control regime:
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• pH
• Temperature
• Nutrients and COD
• Inhibition/ toxicity
Environmental
• Solids retention time
• Hydraulic retention time
• Organic loading rate
• Mixing
Operational
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VFA TA pH
Average 371.38 3,994.78 7.37
Maximum 670.46 4,393.92 7.52
Minimum 205.57 3,492.51 7.18
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
1/1
5
1/2
4
2/2
2/1
1
2/2
0
3/1
3/1
0
3/1
9
3/2
8
4/6
4/1
5
4/2
4
pH
VF
A a
nd
TA
(p
pm
)
Operation Date
Monitoring VFA, TA and pH
VFA TA pH
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CH4 CO2 H2S
Average 60 39 446
Maximum 67 46 943
Minimum 49 35 66
0
100
200
300
400
500
600
700
800
900
1,000
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
1/1
5
1/2
4
2/2
2/1
1
2/2
0
3/1
3/1
0
3/1
9
3/2
8
4/6
4/1
5
4/2
4
H2S
(p
pm
)
CH
4 a
nd
CO
2 (
%)
Operation Date
Monitoring CH4, CO2 and H2S
CH4 CO2 H2S
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Biogas
(Nm3/day) SS (%) Temperature (oC)
Average 9,005.53 41.17 32.89
Maximum 16,562.00 66.92 37.20
Minimum 3,201.00 29.34 27.65
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
0
5,000
10,000
15,000
20,000
25,000
1/1
5
1/2
4
2/2
2/1
1
2/2
0
3/1
3/1
0
3/1
9
3/2
8
4/6
4/1
5
4/2
4
SS
(%
) an
d T
em
p. (d
eg
Cel)
Bio
gas (
Nm
3/D
ay)
Operation Date
Monitoring Biogas, % SS and Temperature
Biogas %SS T
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Biogas
(Nm3/day) CH4 (%)
Average 9,311 60
Maximum 3,201 67
Minimum 16,562 49
0
10
20
30
40
50
60
70
80
0
1,700
3,400
5,100
6,800
8,500
10,200
11,900
13,600
15,300
17,000
1 3 5 7 9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57
59
61
63
65
67
69
71
73
75
77
79
81
83
85
87
89
CH
4 (
%)
Bio
gas (
Nm
3/d
ay)
Operation Days
Monitoring Biogas & Methane
Biogas CH4 Linear (Biogas) Linear (CH4)
KPI = 55 %
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COD LR Eff. COD
Rem.
Average 5.06 77.86
Maximum 7.35 93.66
Minimum 2.42 58.09
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
1/1
5
1/2
4
2/2
2/1
1
2/2
0
3/1
3/1
0
3/1
9
3/2
8
4/6
4/1
5
4/2
4
Eff
. C
D R
em
ov
ed
(%
)
CO
D L
R (
kg
/m3/d
ay)
Operation Date
Monitoring COD LR & Efficiency COD Removed
COD LR Eff. COD Rem.
3. ADIMINISTRATION AND PROCESS MONITORING
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• Standard procedures and guidelines • Operational routine and maintenance schedule • Troubleshooting and corrective measures
• Information management and data processing • Hydrodynamic study • Comparison of data collected • Identification of a progression through the system
• Personnel administration • Effective communication • Organization chart and scopes • Assessment and training
• Operational safety • Safety information and best practices • Emergency action plant
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CONCLUDING REMARKS
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• Primary optimization objectives: • Wastewater treatment targets
• Methane yield and consistency
• Optimizing factors: • Process stability
• Nutrients
• Toxic substrates
• Loading rate
• Digester mixing
• Digester start-up
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Cost effective, accurate real time
monitoring
Programmed control system
Well-trained plant
operators
Practical plant management
strategy
Optimum anaerobic treatment and consistent biogas yield!
• Optimization Strategy:
Today’s Creativity, Tomorrow’s Energy