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Biosystems and Agricultural Engineering
Advancing Utilization of Manure Methane Digester Electrical Generation
Philip Goodrich, R. Vance Morey, David Schmidt, Paul Burns, Matt Drewitz, Dennis Haubenschild, Amanda Bilek, David Nelson
Richard Huelskamp
Advancing Utilization of Advancing Utilization of Manure Methane DigesterManure Methane Digester
Funding for this project was recommended by the Legislative Commission on Minnesota Resources
from the Minnesota Environment and Natural Resources Trust Fund ($204, 375)
Biosystems and Agricultural Engineering
BackgroundBackground
Have a well operating digester on an 800 cow dairy herd
Biogas is being converted to electricity by 130 kW engine generator
Digester is producing excess biogas
Biosystems and Agricultural Engineering
Haubenschild Dairy Farm Energy Haubenschild Dairy Farm Energy ProductionProductionPrinceton, MinnesotaPrinceton, Minnesota
Milk Production + Crop Production + Electrical Production + Future
Hydrogen Production
= Farm Income Diversification
Biosystems and Agricultural Engineering
View of digester, barn and engine generator building at time of installation in 1999.
Biosystems and Agricultural Engineering
Plug-Flow Digester - A small “plug” of slurry is pumped into one end each day, causing a comparable amount to flow out of the other end into the storage basin in the background.
Methane Digester: To breakdown organic matter in the absence of oxygen to biogas, which is primarily CH4/methane, CO2/carbon dioxide, H2S/hydrogen sulfide, and water vapor.
Biosystems and Agricultural Engineering
Engine Generator set:
Internal combustion
engine with 135 kW 240 VAC
electrical generator.
Caterpiller 3406
Biosystems and Agricultural Engineering
Biogas Production Used in Generator
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
09/17/99 09/16/00 09/16/01 09/17/02 09/17/03 09/17/04
Date
Biogas Produced
(ft3/day)
Biosystems and Agricultural Engineering
ObjectiveObjective
Evaluate the feasibility of a fuel cell to convert biogas (methane) to electricity.
Next step may be to produce hydrogen for farm use from biogas.
Biosystems and Agricultural Engineering
Procedures to Achieve ObjectiveProcedures to Achieve Objective
Develop biogas gas cleanup system
Install fuel cell on digesterTest the fuel cellMonitor systems for energy,
consumption and emissions
Biosystems and Agricultural Engineering
ChallengesChallenges
Hydrogen sulfide removal– Initial concentration ~3000 ppm– Need concentration < 25 ppb
Moisture removal– Need dry gas
Carbon dioxide removal– Need concentration < 5 %
Biosystems and Agricultural Engineering
Types of Fuel CellsTypes of Fuel Cells
Proton Exchange Membrane -Low temp
Solid Oxide -High temperature
Molten Carbonate -High Temperature
Biosystems and Agricultural Engineering
A fuel cell is similar to a car battery in that it produces electricity through
electrochemical reactions. A fuel cell produces electricity as long as the hydrogen
fuel source and oxygen passes through it.
Heat is also produced and can be utilized for space heating and hot water needs.
Electricity conversion efficiency is around 25%
The energy resources for hydrogen can be biogas, natural gas, propane, methanol, ethanol, and other hydrogen based liquids or gases.
Biosystems and Agricultural Engineering
The building at the left houses the 135 kW engine generator and the building on the right houses the fuel cell and instrumentation. One barn is to the right rear of the picture
Biosystems and Agricultural Engineering
Fuel Cell: Uses hydrogen to
generate electricity without
combustion. Output is 5 kW at 120 VAC
Biosystems and Agricultural Engineering
Cost per kilowatt is very high.$10,000 -->20,000 per
kW
Biogas must be cleaned up to strict specifications. Adds cost and complexity while consuming energy.
Fuel cell is an emerging technology.
Comparing Electrical Generator Technologies
Engine Generator System
Cost per kilowatt is low. $500 -->1000 per kW
Biogas can be used directly from the digester with no cleanup.
ICE is mature technology.
Fuel Cell System
Biosystems and Agricultural Engineering
Greenhouse emissions and particulates are very low.
System is very quiet.
Few moving parts.
Cost of maintenance is unknown.
Fuel cell technology is continuously improving at a rapid rate.
Comparing Electrical Generator Technologies
Engine Generator System
Greenhouse emissions of CO2, SO2, CO and particulates are significant.
Noise level is very high and sound mitigation is necessary.
Many moving parts, most moving in a hot environment needing oil and cooling.
Maintenance is well known.
Technology is mature and changing slowly.
Fuel Cell System
Biosystems and Agricultural Engineering
Proton Exchange Membrane Fuel Cell (PEM)
Advantages•Could buy one from a vendor with experience•Less expensive than others•Made in lower capacity
Disadvantages•Low temperature water for heating•Critical on gas quality•Lots of gas cleanup needed
Biosystems and Agricultural Engineering
Emissions from Haubenschild Generator Emissions from Haubenschild Generator Compared to Plug Power™ Compared to Plug Power™ Proton Exchange Membrane (PEM) Fuel CellProton Exchange Membrane (PEM) Fuel Cell
( 800ppmv) 4.18 g/kWh
(2960ppmv) 25.5 g/kWh
(277ppmv) 3.34 g/kWh
(20460ppmv) 53 g/kWh
( <1 ppmv) 0.014 g/kWh
(<1 ppmv) <.0023 g/kWh
(<1 ppmv) <0.030 g/kWh
(1790 ppmv) 14.5 g/kWh
Fuel CellEngine Generator
CO
NOx
SOX
CX HY
Biosystems and Agricultural Engineering
Energy Production +
Organic Fertilizer +
Net Air Emissions
=
$nergy Income +
$avings +
Environment Impact Reduction
Biosystems and Agricultural Engineering
Environmental and Economic Benefits
1) reduced reliance on fossil fuels 2) reduced odors and emissions 3) reduced soil and water pollution 4) supports rural economy
Biosystems and Agricultural Engineering
Funding Funding
Funding for this project was recommended by the Legislative Commission on Minnesota Resources from the Minnesota Environment and Natural Resources Trust Fund ($204,375)
Biosystems and Agricultural Engineering
Project Participants
Philip R. Goodrich PE, David Nelson PE, Richard Huelskamp, David Schmidt PE, R. Vance Morey from Department of Biosystems and Agricultural Engineering,
University of Minnesota.
Dennis Haubenschild from Haubenschild Farms, Princeton MN
Matthew Drewitz, Paul Burns, from Minnesota Department of Agriculture
Other participants in this project include:
• Amanda Bilik, The Minnesota Project, • Verlyn Johnson and Blanca Martinez, BAE • Henry Fischer, East Central Energy. • Rob Lowen, Plug Power, Inc. • Jamie Tooley, CES-Landtec Engineering• Don White, Donaldson Corp• David Thimsen, EPRI• Claudio Martinez & Stephan Becerra ,John Deere Co
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