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Biogas CHP - Case Studies and Lessons Learnt
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Biogas CHP Case studies and lessons learnt
Developing UK Biogas ConferenceStoneleigh Park
23rd June 2009Alex Marshall
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Topics
Introduction to Clarke Energy Introduction to GE Jenbacher Engine options Sizing engines for biogas Combined heat and power (CHP) Engine integration with biogas plant
Lessons learnt- H2S & pasteurisation
Biogas case studies Summary
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Introduction to Clarke Energy
Established 1989 Distributor, sales, installation & service
GE Jenbacher HUG
Multinational Sold over 1.7 GW generation capacity Employ 550 people worldwide ISO quality accreditation
ISO9001 Quality Management ISO14001 Environmental Certified
>70% UK gas engine market Unparalleled product support
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Headline figures
The Clarke Group is owned 82% by the Management team and 18% by 3i plc
Turnover of £150m worldwide in 2008 550 employees worldwide Significant growth in China, India and UK
expected in 2009
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Key figures
Equipment Sales37%
Telecom30%
Service / Parts33%
India4%Nigeria
7%
Australia23.4%
France15.5%
UK49.5%
Ireland0.5% China
0.1%
Worldwide group sales
UK sales
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Timeline
89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08E
ST
AB
LIS
HE
D IN
UK
AS
EN
GIN
E S
ER
VIC
E C
OM
PA
NY
ISO
QU
AL
ITY
AC
CR
ED
ITA
TIO
N
JE
NB
AC
HE
R D
IST
RIB
UT
OR
FO
R U
K
DIS
TR
IBU
TO
R F
OR
AU
ST
RA
LIA
, NZ
AN
D N
IGE
RIA
AC
QU
IRE
D C
OG
EN
IND
IA, I
ND
IA D
IST
RIB
UT
OR
AC
QU
IRE
D J
EN
BA
CH
ER
FR
AN
CE
DIS
TR
IBU
TO
R F
OR
IRE
LA
ND
DIS
TR
IBU
TO
R IN
CH
INA
, TU
NIS
IA
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Introduction to GE Jenbacher
Factory located in Jenbach, Austria Roots back to 16th Century 5 decades of experience with gas engines –
first delivered 1957 Only purpose built gas engine supplier 9GW installed power generation worldwide 35% world gas engine market share
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Clarke Energy installed number of GE Jenbacher engines
0 100 200 300 400 500 600 700
UK
France
India
Australia
Nigeria
Number of engines
Biogas Landfill gas Natural gas Mines gas Syngas Flare gas
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Installed GE Jenbacher engine capacity in Clarke Energy territories
0.0 100.0 200.0 300.0 400.0 500.0 600.0 700.0 800.0
UK
France
India
ANZ
Nigeria
Installed capacity - MW
Biogas Landfill gas Natural gas Mines gas Syngas Flare gas
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GE Jenbacher engine options
Engine range 330 – 2,400kW (4,000kW natural gas)
Designed from outset to operate on Natural gas Landfill gas Biogas Mines gas Special gases
Unrivalled: Efficiency (>42%) Durability (>90% availability)
Comprehensive Clarke Energy maintenance package
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Red Queen hypothesis
"For an evolutionary system, continuing development is needed just in order to maintain its fitness relative to the systems it is co-evolving with.“ (L. Van-Valen 1973)
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GE Jenbacher engine models
Type 2 – 250 – 330 kWe
Introduced 1976 – 30 years continuous development
8 cylinder
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GE Jenbacher engine models
Type 3 – 500 – 1,100 kWe
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GE Jenbacher engine models
Type 4 – 800kWe – 1,500kWe
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GE Jenbacher engine models
Type 6 – 1,600 kWe – 4,000 kWe
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Engine sizing for biogas
Engine has fixed energy input Giving
Rated electrical & thermal output Electrical efficiency
3. Assess feedstock to digesters Food waste, energy crops?
Estimate biogas CH4 content Estimate biogas volume Determine biogas energy content
(kW) Select appropriate engine
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What is CHP?
‘Combined Heat and Power (CHP) – is a highly efficient and
environmentally friendly technology for generating heat and power (usually electricity) on site from a single fuel source usually gas.’
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CHP – The basic concept
Overall efficiency – Electrical & thermal – 80-90+%
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How does CHP work?
The basic elements of a CHP plant:1. A prime mover (gas engine)2. Electrical generator driven by the
engine3. Heat exchangers recovering heat from
the engine Jacket cooling water Lubricating oil Turbocharger intercooler Exhaust gases
4. System control panel
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GE Jenbacher gas module
Heat recovery -heat exchanger
EngineEngine control
panelGenerator
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Typical CHP flow diagram
Gas input
Engine hot water circuit
Sec
onda
ry h
eat
ex
cha
nger
Electrical output
Exhaust heat exchanger
Building hot water return
Building hot water feed
Exhaust
Engine hot water circuit
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Energy balance of cogeneration module
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Anaerobic digestion - CHP engine integration
Exhaust heat
Jacket water, oil heat & intercooler
~400ºC
90ºC
Drier
2-300ºCAir
Heat exchanger
Pasteuriser
External heat sink
Digester
District heating Industry
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Pasteurisation unit integration
Pasteurisation
Inflow from buffer tank
Outflow to digesters
Heating water from
CHP
Fill70OC 1hr
Purge
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Hydrogen sulphide
Hazard associated with biogas Originates from protein content of biomass Toxic Impact upon engine
Attacks ferrous metal Lubricating oil acidifies (frequent changes
needed) At very high levels 2,000-4,000 ppm damages
components With condensates acidification occurs
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Hydrogen sulphide solutions
Addition of iron salts to digesterFe2+ + H2S -> FeS + 2H+
Addition of small amounts of oxygen to digester Stimulation of bacteria
Chemisorption technology Iron hydroxide bed Gas scrubber columns Activated carbon
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Case study – Sandon Dock waste water treatment works
Operational 2002 Application – Biogas (sewage sludge) Location: Sandon Dock, Liverpool Client: United Utilities ~1.8MW electrical output
1 x JMC 320, 1 x JMC 312
CHP for digester heating water
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Case study – Jack’s Gulley MBT plant
Installation 2008/9 Application – Biogas (municipal waste) 100,000 tpa mechanical biological treatment
(MBT) plant WSN Environmental – Jack’s Gulley, New South Wales, Australia ~2.8MW electrical output
2 x JMC 420 GS-BL
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Operation & maintenance availability examples
Site CEL Availability
Bilsthorpe 99.6%
Bretby 96.6 %
Brixworth 94.5 %
Enderby Warren 96.3 %
Glapwell 97.8 %
Nant Y Caws 95.4 %
Sutton 97.1 %
Ulnes Walton 95.1 %
Bromborough 96.7 %
Brookhurst Wood 95.3 %
Holiday Moss 98.6 %
Pebsham 97.3 %
Roxby 95.8 %
The above availability % is based upon the maxium achievable running hours in any 1 year – 8,760 hours
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Summary
Clarke Energy is sole UK GE Jenbacher distributor
Engine package needs to be Efficient Reliable
CHP engine integrates with both internally & externally Electrical power Process heat External energy usage
Product support Comprehensive operation and maintenance
package
