Mission Promoting the advancement of anaerobic digestion technology

www.americanbiogascouncil.org


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http://www.biocycle.net/



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Promoting the use of Biogas and Anaerobic Digestion

O

149 Members from the U.S., Germany, Italy, Canada and the UK

O

All Industry Sectors Represented

Key Industry Goals:

O

Promote biogas markets, technologies and infrastructure

O

Achieve policy parity

O Promote as a best practice for environmental stewardship

and greenhouse gas reduction



Changing the Biogas Industry through:o Legislative and Regulatory Affairs ‐

o

Federal: Biogas Tax Credit; Clean Energy

Standard; NAT GAS Act; Farm Bill

o

States: California, Iowa, Massachusetts,

Indiana, more…

o Sharing Expertise –

o 10 Specialized Working Groups

o Education and Outreach ‐

o Briefings, presentations, and webinars for customers, policy makers, and the general public

o Large Industry Network – 145+ company members

o Entire supply chain of production, processing and use


Join Today!

Email Josh Lieberman: [email protected]

or call; 202‐261‐1322

mailto:[email protected]

www.americanbiogascouncil.org 5

Outline

• Introduction ‐

Importance of Digesters –

Shonodeep Modak

• Potawatomi Digester –

Bryan Johnson

• APG1000 Biogas Engine –

Aaron Trexler

• Unison Fuel Treatment –

Jan Scott

• Heat Recovery Solutions –

John Lerch

• Q&A

www.americanbiogascouncil.org 6

Speakers

Shonodeep Modak Global Marketing Manager, GE Energy gas engines

Bryan Johnson, P.E. Renewable/ Sustainable Energy Team Leader, Titus Energy

Aaron Trexler Oil Field Power Generation Product Line Manager, GE Energy gas

engines

Jan Scott President/Co‐Owner, Unison Solutions, Inc.

John Lerch Marketing Manager, Heat Recovery Solutions, GE Energy gas engines

Corey Honl Product Engineering Manager, GE Energy gas engines


Promoting the Anaerobic Digestion and Biogas Industries

Choosing the best technology can make or break your project

Digester Technology Biogas Engine

Technology

Methane

Production Rate

25 ft3/cow/day

35 ft3/cow/day

40 ft3/cow/day

55 ft3/cow/day

60 ft3/cow/day

Pre‐Tax IRR

‐3%

4%

7%

14%

16%

Engine

Efficiency

33%

36%

39%

42%

45%

48%

Pre‐Tax IRR

12%

14%

16%

18%

20%

21%Every 5 ft3/cow/day is worth

2‐3% in IRR Every 3% in efficiency is worth 1‐2% in IRR



Global coverage



Diverse power plant applications



In biogas, we see our

engines as your financial engine

‐10%

‐5%

0%

5%

10%

15%

20%

4,000 6,000 8,000 10,000

Pre‐Tax IRR

Feedstock Volume

2,000

Project Profitability Curve

2,500 head dairy. Project financed by 20% equity, debt at 6% interest for 10 years. 470 kW generator set @

90% availability, 40% efficiency, 40 ft3/cow/day, $0.02/kWh REC, $0.10/kWh PPA, federal treasury grant (ARRA

Sec. 1603). 15 year project life. No added organic waste. CapEx, $2.2M.

Capital Cost/Annualized EBITDA

Internal Rate of Return (IRR)

Investment Metrics

Profitability Drivers Feedstock Size

Power Price

Carbon Price

Finance Structure

Technology Selection

Project Payback



Choosing the best technology can make or break your project

Digester Technology Biogas Engine

Technology

Methane

Production Rate

25 ft3/cow/day

35 ft3/cow/day

40 ft3/cow/day

55 ft3/cow/day

60 ft3/cow/day

Pre‐Tax IRR

‐3%

4%

7%

14%

16%

Engine

Efficiency

33%

36%

39%

42%

45%

48%

Pre‐Tax IRR

2%

4%

6%

7%

9%

10%Every 5 ft3/cow/day is worth

2‐3% in IRR Every 3% in efficiency is worth 1‐2% in IRR



GE’s engines deliver value to your biogas project

Project Scope2,500 head dairy. Project financed by 20% equity, debt at 6% interest for 10

years. 470 kW generator set @ 90% availability, 40% efficiency, 40

ft3/cow/day, $0.02/kWh REC, $0.10/kWh PPA, federal treasury grant

(ARRA Sec. 1603). 15 year project life. No added organic waste.

CapEx,

$2.2M.

η η η η η

Green Energy from Community‐Based Biogas Digesters

June 13th, 2012

Bryan Johnson, P.E.

Renewable and Sustainability Leader



Introduction

• The Forest County Potawatomi Community (FCPC) is developing a 2

MW renewable energy project in downtown Milwaukee, WI

• Anaerobic digestion project using organic feedstock wastes to produce

valuable biogas energy.

• Renewable energy generation is consistent with FCPC’s environmental

goals and values.

• A $2.6 million DOE Community Renewable Energy Deployment grant

was obtained for this project.

• Several renewable technologies analyzed‐

found biogas most feasible.

• When all approvals are obtained, construction will begin later this year

and be completed in 2013.



Project Description• Utilize about 3 acres of land• Former brown field site, originally tamarack swamp

• 10,000 s.f. building• Two digester tank system• Capital budget of ~$18M



Project Concept



Project Planning

• Inputs: organic feedstock supply sources• Siting considerations: locational synergies• Digester technology selection• Electrical CHP generation selection • Plant Outputs: effluent, & digested solids• Project structure: financing and Ownership• Regulatory issues: wastewater permit, air permit



Simplified Digester Process Schematic

Flexible

design for

feedstock

variation

Or Compost

For use or

sale



Digester Input – Organic Feed stocks

• A diverse range of organic materials can be used.

• Identify locally available feedstock materials.

• Develop a plan to cost effectively obtain organic feed stocks.• Material uniformity and source control is an important

consideration.

• Multiple supplies can help balance digester nutrient needs.



Feedstock Biogas Generation Example

Source: Basisdaten Biogas Deutchland, Marz 2005: Fachagentur Nachwachsende Rohstoffe e.V.



Example Feedstock Material Receiving

• Feedstock can be delivered by tanker

trucks as shown.

• Options are solid or liquid form

• Feedstock can be sent directly to

digester or “holding tank”

(with no exposed on‐site storage)

The FCPC Milwaukee digester project will

only accept tanker trucks and all

unloading will occur inside the building

structure.(no outside operations)



Biogas Engine Generator Selection

• Biogas engines have a long‐time

established track record.

• The Milwaukee digester project is

sized for 2 MW.

• Two GE Waukesha APG1000 high

efficiency integrated cogeneration

lean burn biogas engines selected for

project.

• GE Waukesha met critical project

criteria and delivery requirements.

• Requires gas conditioning to filter,

remove moisture, H2

S and test for

other contaminates.



FCPC Biogas Engine Rating

LHV of Fuel (min) BTU/SCF 400

Engine Power BHP 1402

Engine Efficiency % 41.3%

Thermal Efficiency % 46.0%

Total Efficiency* % 85.7%

Electric output per engine MW 1.0

Available heat water jacket MMBtu/hr. 2.53

Available heat exhaust (to 350 deg f) MMBtu/hr. 1.44

Power/Heat Generation‐

GE’s Waukesha APG1000

Note: GE Waukesha APG1000 was developed as part of a DOE program to produce the next generation of

high efficiency IC engines by U.S. manufacturers.



Community Digester Benefits and Summary

• Anaerobic digestion and biogas generation proven technology

• The FCPC Community Digester will utilize available

organic feedstock wastes to produce valuable energy.

• Electrical CHP generation will benefit FCPC with an economical means to produce renewable energy

• Environmental benefits achieved• Waste minimization

• Supports independence from fossil fuels

• GHG reductions

GE‘s Waukesha APG1000



Features Description Advantage

Efficiency Optimized Miller cycle combustion, low flow

loss engine breathing, specific turbocharger

matching and high efficiency generators, class

leading electrical efficiency of 41.7% @60 Hz

Higher electrical efficiency

maximizes return on investment

Emissions Availability of two different NOx emissions

settings for 50/60 Hz allows for application

flexibility (1g/TA Luft & 0.6g/1/2 TA Luft)

Optimized efficiency at each

emissions rating

Packaging Overall engine/genset envelop supports

containerization with a CHP package available

providing 89.4% efficiency

Ability to create a compact and

portable genset solution

Fuel control Biogas fuel system optimized to handle

changing fuel quality with heating values of

400‐650 BTU/ft3 (15.73‐25.56 MJ/Nm3)

Application flexibility, minimal

manual intervention, increased

uptime/availability, maximizes

return on investment



5 products for waste‐to‐energy applications (60 Hz)

0 1000 2000 3000 4000

Jenbacher type 3

Jenbacher type 4

Jenbacher type 6

Waukesha APG 1000

Jenbacher type 2

APG 1000

J208

Electrical output range (kW)

J312 J316 J320

J412 J416 J420

J612 J616 J620



Scope

Enginator* • Bare engine + generator• Engine mounted JW & AUX pumps

& thermostats

• Optional high efficiency generator

Enginator* w/CHP

configuration

• Increased thermal efficiency• Plate & frame heat exchanger• ECP8000E control panel• Ethernet connection for panel

controls

Bare engine • ESM controls w/AFR• Optional biogas fuel system• Optional exhaust & main bearing

thermocouples



Container‐friendly overall engine design

201in(5,105mm)

70.87in1,800mm



Low profile air filter easily fits within container enclosure

without modification



Single turbocharger combined with Miller Cycle technology reduces

fuel consumption for a higher return on investment

32GE Energy – Gas Engines APG1000 Presentation

Launch Event 2012

Optimized biogas‐specific fuel

control system•Little user interaction•Easy engine starting•Increased fuel flexibility•Maximized uptime

33GE Energy – Gas Engines APG1000 Presentation

Launch Event 2012

Optimized biogas‐specific

fuel control system

provides customer

“peace‐of‐mind”

Fuel control valveAdjusts to changes in biogas

composition, minimizing operator

interaction

Gas regulatorMaintains constant fuel

pressure from commonly

unstable fuel source for

optimal engine performance

Double blocking valveTwo safety shutoff valves

includes a valve proving

system to ensure safe

operation



The APG1000 1.1 MW Enginator CHP package allows for optimized

efficiency by maximizing heat recovery. CHP components are

factory mounted, minimizing installation time and cost.

Low temp circuit has a return temperature of 130°F• Very little waste, small size radiator for discharging

remaining waste heat

High temp circuit has a supply temperature of up to 230°F

Full featured CHP control panel to control ancillary equipment

High efficiency ‐

41.7% electrical &

89.4% total



Four Waukesha APG1000 containerized Enginators have been running at Hampton Downs Landfill in New Zealand since 2009, providing an output of 4,400 kWe.

Hampton Downs Landfill



Helchtern, Belgium ‐

The animal waste biogas is processed in 2 – 1MW

APG1000 gas CHP units. The manufactured heat and electricity is

partially delivered to a nearby located recreation park Molenheide. The

remaining heat is used for bio processing, electricity is fed to

the grid.

Project Storg/P. Lavrijsen



In Cavite City, Philippines, an APG1000 Enginator running on digester

gas produces 1100 kWe of electricity, is used for farm operation.

Excess electrical output is sold to the local grid and the heat

produced is used for the incubators. This site was named one of the

“World’s Best Power Plants”

in the January ‐

February 2010 issue of

Diesel & Gas Turbine Worldwide.

Cavite City, Philippines



The Forest County Potawatomi Community project will include

installation of a biogas generation plant on Tribe‐owned land in

Milwaukee County.

Unison Solutions, Inc.Unison Solutions, Inc.Biogas Treatment SystemsBiogas Treatment Systems

American Biogas Council WebinarAmerican Biogas Council WebinarSaving Cities With Waste Power:Saving Cities With Waste Power:

Putting Biogas To WorkPutting Biogas To Work

June 13, 2012 June 13, 2012

Complete System Process Flow DiagramComplete System Process Flow Diagram

BiogasSource

HydrogenSulfideRemovalSystem

Gas Blower/Moisture

Removal

System

SiloxaneRemovalSystem

End UseEquipment

GlycolChiller

ElectricalControlPanel

Hydrogen Sulfide RemovalHydrogen Sulfide Removal

Fixed Bed Media SystemsSulfaTreat

Iron Sponge

Biological Systems

Iron Sponge / Biological Systems

SulfaTreat/Iron Sponge ProcessSulfaTreat/Iron Sponge Process

Biogas containing

Hydrogen sulfide (H2

S)

Media: Sulfatreat or

Iron Sponge

Water to Drain Biogas free of

Hydrogen Sulfide (H2

S)

Gas Compression/Moisture Removal SystemGas Compression/Moisture Removal System

Gas Blower Inlet

Moisture/

Particulate Filter

Rotary Lobe Positive

Displacement Blower

Multistage

Centrifugal Blower

Forced Air To Gas

Heat Exchanger

(Optional)

Dual Core

Heat Exchanger

Glycol Chiller

OR

Siloxane Removal TechnologiesSiloxane Removal Technologies

Fixed Bed Activated Carbon MediaCoal Based

Coconut Shell

Regenerable System

Fixed Bed Activated Carbon Media ProcessFixed Bed Activated Carbon Media Process

Biogas with

Siloxanes ‐

H2

S has

been removed

Carbon media ‐

Type is

determined based on

siloxane levels

Biogas ready

for use

Siloxane Damaged PistonSiloxane Damaged Piston

Waukesha APG 1000 Standard PackageWaukesha APG 1000 Standard Package Key ComponentsKey Components

Optional Hydrogen Sulfide Removal

Gas Compression/Moisture Removal

Optional Siloxane Removal

Glycol Chiller

Electrical Control Panel

Waukesha APG 1000 Standard PackageWaukesha APG 1000 Standard Package

Electrical Control Panel

GlycolChiller

SiloxaneRemoval

HydrogenSulfideRemoval

Gas Compression/Moisture Removal

Typical Completed InstallationTypical Completed Installation

TEST AND TREAT YOUR BIOGAS!


Promoting the Anaerobic Digestion and Biogas IndustriesPromoting the Anaerobic Digestion and Biogas Industries

Benefits

• One unit generates up to 125kW of electricity from a heat source

• Heat is the only input; no additional fuel required or emissions

generated

• Low maintenance: magnetic bearing generator, no lubricants, no overhauls

• Minimal operation required: automatically load follows heat source including start & stop

• Electricity generated at power factor of 1

Specifications

Power

up to 125kWe gross

Heat Inputs

~980kWth (3.34 MBtu/hr)

Min. Input Temp

121˚C (250˚F)

Dimensions

200 x 285 x 117cm

79 x 112 x 46in

Clean Cycle heat to power generator



Clean CycleTM

technology is based on the Organic Rankine Cycle (ORC), which utilizes an organic

working fluid with a lower boiling point than water to generate electrical power from heatThe cycle is closed loop – there is no combustion and no emissions

Heat Source

Recip Engines

Biomass Boilers

Microturbines

Other / Industry

Organic Rankine Cycle: how it works



Engine Clean CycleHeat

exchangers

Condenser

Benefits of a Clean Cycle installation on an engine:

•Increases total installation electrical output by up to 10%

•Increases total system electrical efficiency by up to 5%

•Very low OpEx: no fuel, no major overhauls, manned supervision not required

Clean Cycle increases engine output



Clean Cycle

Exhaust gas heat

exchangerHot water loop

Condenser

Reciprocating engine

• Clean Cycle ‘skid’

represents ~40% of installation

• Modular, turnkey system (20ft container) available

• Clean Cycle ‘skid’

represents ~40% of installation

• Modular, turnkey system (20ft container) available

Anatomy of a Clean Cycle installation



Rules of thumb

•~900kWth runs the Clean Cycle at full load, so that’s a 1‐1.5MW engine

•Heat sources from multiple engines can be combined to get more heat input, if needed

•Multiple Clean Cycle generators can run on a single heat source,

if enough heat is available

•Clean Cycle follows the heat source if it fluctuates, turns off,

or on

IsraelLandfill Gas2 J320 engines

Czech RepublicBiogasJ420 engine

UKLandfill2 J320 engines

Ocala FL, USALandfill GasCat 3520

Slovenia2 biogas plants1 biodiesel recip

ItalyLandfill gas2 J320 engines

AustriaNatural gasJ412 engine

GermanyBiogasJ416 Engine

Example engine installations



Integrated Power Module

Proven

•Fleet of ORC’s in operation in countries across the globe•110,000+ operating hours•Leverage in‐house engine knowledge and compatibility

•Simple, low maintenance

Proprietary technology enables

•No gearbox•No external seals•No lubrication•Non‐contact magnetic bearings

•Variable speed and power –

follows the heat source

•Power factor of 1 – makes using or selling electricity easier

The Clean Cycle advantage

QuestionsAsk questions using the Questions Panel on the right side of your screen.

All questions and comments will be recorded and incorporated in the webinar summary report.

Also, please take a few moments to answer the survey questions.




http://www.biothane.com/en/

More Information• This Webinar will be available

by Monday, June 18

• Sign up

to receive ABC news at on our website,

www.americanbiogascouncil.org.

• Consider Joining ABC‐‐Receive regulatory and policy intelligence‐‐Connect with other biogas and anaerobic digestion

leaders‐‐Support the industry’s growth and outreach

http://www.americanbiogascouncil.org/

Thank You

Paul Greene, ABC Chairman

[email protected]

(518) 758‐2179

Patrick Serfass, ABC Executive Director

[email protected]

(202) 640‐6595




http://www.americanbiogascouncil.org/

Documents

Mission Promoting the advancement of anaerobic digestion technology