evaluating anaerobic digestion projectsamericanbiogascouncil.org/biocycleworkshop/mcdonald.pdf ·...
TRANSCRIPT
DESIGN AND CONSTRUCTION OF AD PLANTS34 FULL-SCALE PLANTS ON:34 FULL-SCALE PLANTS ON:
- FOOD/BIOWASTE: 14 DRANCO PLANTS (S/U 1992)14 DRANCO PLANTS (S/U 1992)
- RESIDUAL/MIXED WASTE: 10 DRANCO PLANTS (S/U 1997)( )
- ENERGY CROPS: 1 DRANCO-FARM PLANT (S/U 2006)
- ENERGY CROPS/FOOD WASTE/MANURE: 9 WET ADWASTE/MANURE: 9 WET AD PLANTS (S/U 2005)
Five sites under constructionFive sites under construction
2
INNOVATORS IN USE OF BIOGAS, ENERGY AND DIGESTATEAND DIGESTATE
• Biogas -> Electricity + District Heat + Wood Drying D Ch T Hi h T l A i lt+ Dog Chew Toys + High Tunnel Agriculture
• First interconnected biogas plant in many locationsFi t US d i bi t i li i ti (75• First US dairy biogas to pipeline insertion (75 scfm)
• First Quad Generation Biogas Plant• First Quad-Generation Biogas Plant • First US dairy biogas to RCNG (775 GDE/day)• World’s largest AD biogas to RNG (at the time)• World s largest AD biogas to RNG (at the time)• Digestate -> Bedding -> Compost -> Fertilizer
Pellets -> RDF fuelPellets > RDF fuel
SUCCESS STORIESSUCC SS S O S
• Reference plants in 14 different countries, treating source-separated and mixed-household waste, industrial and commercial waste organics, as well as energy crops. • “Senior” plant has demonstrated 99.59349% in-service, active digestion time over the last 20 years!active digestion time over the last 20 years!• Managed/advised >150 plants we did not build
TECHNICAL MERITFEEDSTOCKS EQUIPMENT• FEEDSTOCKS– QUANTITY– QUALITY
CONSISTENCY/
• EQUIPMENT– INSTALLATION– OPERATIONS/
MAINTENANCE– CONSISTENCY/ SEASONALITY
– SECURITY/CONTROL
MAINTENANCE
• VENDORS/SUPPLIERSRELEVANT EXPERIENCE
• PROCESS– FLEXIBILITY– COMPLEXITY
– RELEVANT EXPERIENCE– EXPERIENCED
PERSONNEL ON YOUR PROJECTCOMPLEXITY
– RELIABILITY
• SITE
– ABILITY TO BACK PERFORMANCE WARRANTY, REMAIN IN BUSINESSSITE
– FOOTPRINT RESTRICTIONS
– HEIGHT RESTRICTIONS – REGULATORY/PERMITS– INTERCONNECTION
ECONOMIC MERITCOSTS AMOUNT BENEFITS• COSTS – AMOUNT AND PREDICTABILITY
• BENEFITS -AMOUNT AND PREDICTABILITY
– FEEDSTOCK COST– PROCESSING COST
– PRODUCTIVITY– ON-SITE SAVINGS
– SITE ACQUISITION/ PREPARATION
– PERMITTING
ON SITE SAVINGS– OFF-SITE
REVENUESPERMITTING PROCESS
– EQUIPMENT • INITIAL PURCHASE
• FUNDING SOURCES
AMOUNT AVAILABLEINITIAL PURCHASE• REPAIRS• REPLACEMENT
– GRANTS
– AMOUNT AVAILABLE– CONDITIONS– FINANCING COSTGRANTS
DEFINITION OF SUCCESSFUL PROJECT
• Project works • ProjectProject works technically most of the time
Project technologyadapts toof the time,
within narrow process window
adapts to changing conditionsprocess window
• Can make payments/cover
co d t o s• Market ROR• Lower ratespayments/cover
costs• Lower rates
for community
COMPOSITION OF INCOMING WASTEWELL UNDERSTOOD
MADISON, WISCONSIN SSOWSSOW
Distribution of sorted waste (fresh weight): inner ring: 1st sample outer ring: 2nd
samplesample
KEY ELEMENTS OF SUCCESSFUL PROJECTS
• High Feedstock Security and Predictability– Which is more important?
• Cost/tipping fee per tonpp g p• Quantity per week or year• Composition• Composition
Complete Mix Digester - 3-20% dry matter
DRANCO – 35-55% dry matterOWS, n.vAPPROPRIATE DIGESTER DESIGN
Scenic View Dairy, Fennville, MI. Photo courtesy of Phase 3 Renewables
Horizontal plug flow – 15-30% dry matterOWS, n.v
FACTOR WET DIGESTION BATCH TUNNEL DRY CONTINUOUS
PARTICLE SIZE
PUMPING COMPACTION PUMPINGSIZE
MIXING, FLOATING, SETTLING
POROSITY, PERCOLATION
RATE OF DIGESTION
RATE OF DIGESTION ZONES WITHIN PILE
DEWATERING RATE OF DIGESTION
LIGHT FRACTION
FLOATING LAYER PERCOLATION, POROSITY
BIOGAS/TON
BIOGAS/TON BIOGAS/TON
HEAVY FRACTION
SEDIMENTATION COMPACTION, PERCOLATION
BIOGAS/TONFRACTION PERCOLATION
BIOGAS/TON BIOGAS/TON
SOLIDS CONTENT
8‐13% 45% ‐ 55% 25% ‐ 50%
KEY ELEMENTS OF SUCCESSFUL PROJECTS
T h l d E i t P id• Technology and Equipment Provider Remains a Positive Factor– On time, on budget– Sufficient support for startup, performance
t t i titest, ongoing operations– Quickly addresses issues or new conditions– Financial strength to back warranties
Why have projects failed –t h i ll i ll b th?technically, economically or both?
• DESIGN-RELATED:– INAPPROPRIATE DESIGN– FLAWED DESIGN
FEEDSTOCK RELATED• FEEDSTOCK-RELATED– QUANTITY SHRINKS– CHARACTERISTICS CHANGE (impacting material handling,
energy potential)
• MANAGEMENT-RELATED– INSUFFICIENT FUNDS– INSUFFICIENT FUNDS– IMPROPER OPERATION– INSUFFICIENT MAINTENANCE
INADEQUATE SITE PLANNING
PUMPAGIT
PUMP
BARNS
DIGESTER
GENSET/BOILERCONTROLS
SITE PLANNING-Location of existing
and proposed PUMP
FLARE
facilities, energy use-Determine process
flow and footprint
STORAGE-DISTANCE-ELEVATION p-PRESSURE DROP-GPM/GPD NEEDSSOIL BEARING-SOIL BEARING
-MONITORING- STORAGE
REDUNDANCY-REDUNDANCY-UTILITY INFRASTRUCTURE
Flame Flame Arrestor
Flame Arrestor
Flame Trap with
Flame Arrestor Flame
Arrestor
with Thermal Shut-OffFlame Trap
with ThermalThermal Shut-Off Waste Gas
Burner or Flare
Flame
Flame Trap with Thermal Shut-Off
Flame Check
TROUBLES COME NOT AS SINGLE SPIES, BUT IN BATTALLIONS - ShakespeareIN BATTALLIONS Shakespeare
“All it took is 5 years and $150,000,000 from 215 shareholders to see y , ,(EPGRQ.PK) going bust. The reason is very simple - debt. If you think that Crude Oil will reach over $144 a barrel in a short time then their financials will get better (margins increase) and it can change everything but as you see at current oil prices they can't turn a profit $46 5M in debt with $4 7Msee at current oil prices they can t turn a profit - $46.5M in debt with $4.7M in yearly revenues.”
DEFINITION OF SUCCESSFUL PROJECT
• Project works • ProjectProject works technically most of the time
Project technologyadapts toof the time,
within narrow process window
adapts to changing conditionsprocess window
• Can make payments/cover
co d t o s• Market ROR• Lower ratespayments/cover
costs• Lower rates
for community
RECOMMENDATIONSRECOMMENDATIONS
• Run risk-adjusted pro-formasRun risk adjusted pro formas• Run failure mode analysis early in
engineering processengineering process• Obtain reasonable assurances• Place appropriate value on track record