ms biogas roundtable-greg sorge
TRANSCRIPT
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Biogas Engine Application
Greg Sorge
Charles Equipment Company5/26/05
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Company Information
Since 1960, CEC has beenspecializing in energy systems forbusiness, homes andmunicipalities.
Wide range of applications include:landfill gas to energy, skyscrapers,hospitals, airports, schools anduniversities, sewage, wastewater
treatment facilities, police and firestations, and communicationcenters.
Everything you need in one place.
With you throughout the project.
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Products Generator Sets
Controls
Heat Recovery
Cooling Exhaust
Fuel Compression and Processing
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Service Offering Engineering
Assess customer needs.
Provide complete turn-key package for any application.
Training
Maintenance Programs
From oil changes to major overhauls. CEC can tailorprograms for monthly, quarterly or semi-annual
depending upon the application.
Emergency Service
CEC provides 24-hour emergency service for engines,
driven components and generators, not just those wesell.
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Waukesha Biogas Experience
Since 1985 there are 400 Waukesha enginesproducing 280,000 kWe with bio-gas fuels
worldwide.
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Wisconsin Biogas Projects
Burlington WWTP Eau Clarie7-Mile
Landfill
Five Star Dairy
Glacier Ridge Landfill
Janesville WWTP Janesville Landfill
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Wisconsin Biogas Projects
Kenosha WWTP Kenosha Water Utility
Madison WWTP
Outagamie County
Landfill
Racine WWTP Wild Rose Dairy
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Power Generation Equipment
Cost vs. Size Power generation equipment that is
operated connected to utility power has
certain fixed costs that are irrespective ofsize. This includes generator controls andutility protective relays.
These fixed costs and economics of scale ofthe generation equipment result in highercosts per kW in smaller units.
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Power vs Equipment CostsGenerator Set, Controls, Heat Recovery,
Fuel Drying and Compression
Not including enclosure, construction and installation
$-
$500
$1,000
$1,500
0 200 400 600 800 1000 1200
Power kWe
EquipmentCost
$/kW
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Maintenance Affected by Biogas
Operation
Oil Change Intervals
Valve Adjustment Intervals
Fuel System Adjustment Intervals
Valve Overhaul Intervals
Major Overhaul Intervals
Fuel System Repair Intervals
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Agricultural Digester Fuel
Contaminants Hydrogen Sulfide
Water
Solid Debris
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Hydrogen Sulfide In Digester Gas
Produced in the digestion process. Absorbs in water forming a weak acid corrosive to
piping and equipment.
Burns in combustion to SO2 then combines withwater forming a very strong acid: sulfuric acid
(H2SO4)
Sulfuric Acid is corrosive to engine and heat
recovery equipment.
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Tolerance to H2S and H2SO4
Minimize use of yellow metals such as brass,bronze, and copper in engine components that
contact combustion gas or lube oil.
Use high TBN (Total Base Number or alkalinityreserve) lube oils to prevent oil from becoming
acidic.
Raise coolant temperature to reduce condensation
of H2SO4.
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Sulfuric Acid Boiling Point
Biogas engines operate at high temperaturesto avoid condensation of acids.
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Sulfuric Acid Boiling Point
Biogas engines operate at high temperaturesto avoid condensation of acids.
What temperature does pure sulfuric acidboil at?
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Sulfuric Acid Boiling Point
Biogas engines operate at high temperaturesto avoid condensation of acids.
What temperature does pure sulfuric acidboil at?
638F
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Sulfuric Acid Concentration vs. Boiling Point
Sulfuric Acid Saturation Concentration in Gas
vs Temperature
0.01%
0.10%
1.00%
10.00%
100.00%
Temperature F
C
oncentration
200 400 600 8000
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H2S Concentration in Fuel vs. H2SO4
Condensation Temp. in Exhaust
150
200
250
300
350
0 2000 4000 6000 8000 10000 12000
PPMv H2S
S
ulfuricAcidCondensation
Temper
atureF
Condensed sulfuric acid
Vaporized sulfuric acid
210F
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Water in Biogas
Water is formed in the digestion process resulting in
saturated gas at the digestion temperature.
Saturated gas at 95 F is 5.5% water vapor.
Saturated gas at 140 F is 20% water vapor.
Condensed water from the fuel for a 100 kW generator is
0.5 to 2 gallons/hour, 4400 to 18,000 gallons/year.
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Waters Impact on Engine Operation
Water condensation in fuel piping causes corrosion, and
builds up on carburetor and regulator diaphragms taking
fuel system components out of calibration.
Water condensation in the combustion chamber washes
lubricating oil off cylinder walls resulting in higher wear.
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Debris in Digester Gas
Debris can result from digester influent, digester additives
for H2S control, fabrication of fuel piping, and from
corrosion of piping and fuel handling equipment.
Debris in the combustion chamber causes abrasive wear.
Debris is easily removed by filtration.
The coalescing filter used for water removal will also
remove debris.
A particulate filter may be desired to reduce the cost of
replacing coalescing filter elements.
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Biogas Processing
Costs for removing H2S, water, and debris vary widely
and can become prohibitive when pursuing complete
removal.
H2S is soluble in water (0.5 g H2S /100 ml water @ 67 F)
and a portion of it can be removed by condensing water.Reducing water vapor from 5.5% to 1% by chilling to 40 F
and coalescing, could remove approximately 200 ppm
H2S.
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Biogas Processing Minimum System: Condensed water, dissolved H2S, and
debris are removed prior to entering the blower. Water vaporcontent in the gas is 5.5% for a 95 F gas temperature. The
blower pressurizes and heats the gas resulting in dry gas
(
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Biogas Processing
Improved System: Gas is chilled to 40F then passes
through a coalescing filter for removal of condensed water
and dissolved H2S. Gas is then pressurized and heated in a
blower before entering the engine. Cooling to 40F reduces
water vapor content in the gas to
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Biogas Processing
Ideal System: Gas passes through an H2S removal system,
particulate filter, then is cooled to 40F, liquid removed in a
coalescing filter, then pressurized and heated in a blower.Blower
Engine
0.3 micron coalescing filter
Glycol chilledheatexchanger
Particulate Filter
H2S Removalsystem
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Summary
Operation with biogas reduces service intervals compared
to natural gas operation. Water, H2S, and debris removal are important for
minimizing operating and maintenance costs.
3 levels of gas processing were presented and discussed.