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By: Giovanni Rumbolo, Peter Monko, Shimolee Nahar, Xiaoqian Ruan
Project Sponsor: Dr. Raj Rajaram
UGL Tech Team 2 Final Presentation
Recap of Project Goals
Identify and select a technology for AD to be installed in Bronzeville locality
Research gas cleaning and electricity generation technologies
Identify the gas and other by-product markets
Food waste
Source: EPA organic waste treatment
Waste Profile of Bronzeville
Bronzeville, which is part of ward 3, waste generation range lies from 5000-15000 tons/day.
Type of organic waste available in abundance – baked goods, expired produce, fats, oils & greases
Major sources of feedstock: Super markets/grocery: Jewel
Osco, 7 Eleven, Restaurants: many in Chinatown, University cafeterias: 4-5 , Food Manufacturers: 10-12
Sources: Chicago waste characterization study, 2010 Interview with Zeropercent founder Google map data
FEEDSTOCK PRE-TREATMENT SYSTEM
Overview
04/18/23
Feedstock Pretreatment Contaminants in the feedstock reduces biogas generation, creates a low
value digestate and can interrupt the fermentation process causing maintenance problems.
Technologies Available: grinders, tromells with sieves, magnets, mills, pulpers, screw presses.
ContaminantsBiogas revenueTipping fees
Capital costs
M & O costs
Waste hauling
Recommended Pretreatment Plan
1.Manual separation of large non-desirables2.120 mm Trommel with blades inside to deal with large items3.Trommel with 60 mm sieve 4.Magnetic separator5.Manual separation of plastic and other non-organics6.Grinder with 45 mm sieve
ANAEROBIC DIGESTER TYPES
Overview
04/18/23
Comparing Types of AD Systems
Site Specific need identification: Type of feed stock => amount of pretreatment needed System design optimization: loading rate, operating temperature,
wet/dry Amount of food waste processed and annual gas yield Types and quality of by-products is the system going to generate
and potential markets for the same in and around Chicago
Researched local and international MSW case studies. Compared the models against the site specific needs: Cold winters, small footprint, limited digestate market, small tipping fees
Technology Wetor Dry
Solids LoadingRange
Type of Reactor Temperature Amount of Waste processed
Annually (tons/year)
Retention time(days)
Amount of biogas
generated(Nm3/metric ton of feed)
Pretreatment needed
Eisenmann Dry 20-40% Horizontal dualStage
Mesophilic 12,000 23 146 Yes
DRANCO Dry up to 40% Single Stage, vertical
Thermophilic 120,000 20 133 Yes
KompoGAS Dry 23-28% Horizontal SingleStage
Thermophilic 13,000 14 130 Yes
Valorga Dry 40-45% Vertical, single stage Mesophilic 240,000 21 114 Yes
BTA Wet 8-9% Vertical, single stage Mesophilic 42,500 23 120 Wet Pretreatment
Comparison of Existing Anaerobic Digester Technologies
Apart from the parameters – Key decision criteria is revenue generated from either electricity using CHP system or refined natural gas
CHP SYSTEMMarket Option 1 - Electricity Generation
04/18/23
On-site CHP system
One potential solution for the biogas byproduct was the use it to power a combined heat & power system on-site.
This solution would help limit the operating cost of Urban Green Loop and would provide the option of selling renewable energy back to the grid and maximize revenues (RECs)
Our research, based on capital and O&M, suggested three CHP options: Steam Turbine Gas Combustion Engine Micro-turbines
Due to limited biogas refinement needed, reduced capital/M&O costs, and extensive case history the gas combustion engine option would be our recommendation.
Combined Heating and Power (CHP) Biogas Utilization System Overview
Source: http://www.epa.gov/chp/basic/
CharacteristicSteam
Turbine
Gas/Combustion
TurbineMicro-turbine
ReciproprocatingIC Engine Fuel Cell
StirlingEngine
Size50 kW to250 MW
500 kW to40 MW
30 kW to250 MW < 5MW < 5MW < 200 kW
Fuels Biogas Biogas Biogas Biogas Biogas Biogas
Fuel Preparation NonePM filter needed
PM filter needed
PM filter needed Yes None
Sensitivity to fuelmoisture N/A Yes Yes Yes Yes No
Electric efficiency 5 to 30% 22 to 36% 22 to 30% 22 to 45% 30 to 63% 5 to 45%
Operating issues
High reliabilityslow start-up
long life,maintenanceinfrastructure
readily available
Highreliability,high-grade
heat available,no cooling required
requires gascompressor
maintenanceinfrastructure
readily available
Fast start-up,requires fuel gas
compressor
Fast start-up,good load-following
must be cooledwhen CHP heat
is not used, maintenance infrastructure
readily available, noisy
Lowdurability,low noise
Low noise
CommercializationStatus
Numerousmodels
available
Numerousmodels
available
Limitedmodels
available
Numerousmodels
available
Limitedmodels
available
Limitedmodels
available
Installed cost
$350 to$750/kW
(w/o boiler)$700 to
$2,000/kW$1,100 to
$2,000/kW$800 to
$1,500/kW$3,000 to
$5,000/kW$1,000 to
$10,000/kW
O&M costs <$0.004/kWh$0.006 to
$0.011/kWh$0.008 to
$0.02/kWh$0.008 to
$0.025/kWh$0.01 to
$0.04/kWh ~$0.01/kWh
Existing Combined Heating and Power Technologies
Source: EPA Catalog of CHP Technologies, 2004
10 tons/day 20 tons/day 100 tons/day
Steam Turbine
Biogasgeneratedannually
(kWh)
ElectricityGenerated
(kWh) Revenue* ($)
Biogasgeneratedannually
ElectricityGenerated Revenue* ($)
Biogasgeneratedannually
ElectricityGenerated Revenue* ($)
Eisenmann 5,153,143.00 1,545,942.90 83,790.11 10,306,286.00 3,091,885.80 167,580.21 51,531,430.00 15,459,429.00 837,901.05DRANCO 4,694,301.50 1,408,290.45 76,329.34 9,388,603.00 2,816,580.90 152,658.68 46,943,015.00 14,082,904.50 763,293.42KompoGAS 4,588,415.00 1,376,524.50 74,607.63 9,176,830.00 2,753,049.00 149,215.26 45,884,150.00 13,765,245.00 746,076.28Valorga 4,023,687.00 1,207,106.10 65,425.15 8,047,374.00 2,414,212.20 130,850.30 40,236,870.00 12,071,061.00 654,251.51BTA 4,235,460.00 1,270,638.00 68,868.58 8,470,920.00 2,541,276.00 137,737.16 42,354,600.00 12,706,380.00 688,685.80
Gas/CombustionEngine
Eisenmann 5,153,143.00 1,855,131.48 100,548.13 10,306,286.00 3,710,262.96 201,096.25 51,531,430.00 18,551,314.80 1,005,481.26DRANCO 4,694,301.50 1,689,948.54 91,595.21 9,388,603.00 3,379,897.08 183,190.42 46,943,015.00 16,899,485.40 915,952.11KompoGAS 4,588,415.00 1,651,829.40 89,529.15 9,176,830.00 3,303,658.80 179,058.31 45,884,150.00 16,518,294.00 895,291.53Valorga 4,023,687.00 1,448,527.32 78,510.18 8,047,374.00 2,897,054.64 157,020.36 40,236,870.00 14,485,273.20 785,101.81BTA 4,235,460.00 1,524,765.60 82,642.30 8,470,920.00 3,049,531.20 165,284.59 42,354,600.00 15,247,656.00 826,422.96
Microturbine Eisenmann 5,153,143.00 1,545,942.90 83,790.11 10,306,286.00 3,091,885.80 167,580.21 51,531,430.00 15,459,429.00 837,901.05DRANCO 4,694,301.50 1,408,290.45 76,329.34 9,388,603.00 2,816,580.90 152,658.68 46,943,015.00 14,082,904.50 763,293.42KompoGAS 4,588,415.00 1,376,524.50 74,607.63 9,176,830.00 2,753,049.00 149,215.26 45,884,150.00 13,765,245.00 746,076.28Valorga 4,023,687.00 1,207,106.10 65,425.15 8,047,374.00 2,414,212.20 130,850.30 40,236,870.00 12,071,061.00 654,251.51BTA 4,235,460.00 1,270,638.00 68,868.58 8,470,920.00 2,541,276.00 137,737.16 42,354,600.00 12,706,380.00 688,685.80
Biogas Revenue Generated
Assumptions:Spot price for natural gas in Chicago May 2014 (EIA) - $4.69/mmbtu or $ 0.0160/kWhElectricity price is based on Integrys Chicago contract - $0.0542/kWh1 mmbtu = 293.1 kWhSource: http://www.eia.gov/naturalgas/weekly/#tabs-prices-2
GAS PURIFICATION SYSTEM
Market Option 2 – Gas Sales
04/18/23
Biogas Cleaning Technology
Source: American Biogas Council
04/18/23
General Standards for Natural gas
heating units >1,000 Btu per cubic foot of gas
ComponentTypical Analysis
(mole %) Range
(mole %)
Methane 94.9 87-96
Ethane 2.5 1.8-5.1
Propane 0.2 0.1-1.5
Iso-Butane 0.03 0.01-0.3
Normal-butane 0.03 0.01-0.3
Iso-Pentane 0.01 trace-0.14
Normal-Pentane 0.01 trace-0.04
Hexanes plus 0.01 trace-0.06
Nitrogen 1.6 1.3-5.6
Carbon Dioxide 0.7 0.1-1.0
Oxygen 0.02 0.01-0.1
Hydrogen trace trace-0.02
Specific Gravity 0.585 0.57-0.62
Gross Heating Value (MJ/M3), dry basis 37.8 36-40.2
04/18/23
Costs of Technology
Only feasible at the volume of >20tons/day
Source: BioCNG
04/18/23
Revenue from compressed gas
10 tons/day 20 tons/day 100 tons/day
Steam Turbine
Biogasgeneratedannually
(kWh)
Compressed Methane
generated(kWh) Revenue* ($)
Biogasgeneratedannually
(kWh)
Compressed Methane
generated (kWh) Revenue* ($)
Biogasgeneratedannually
(kWh)
Compressed Methane
generated (kWh) Revenue* ($)
Eisenmann 5,153,143.00 3,091,885.80 49,470.17 10,306,286.00 6,183,771.60 98,940.35 51,531,430.00 30,918,858.00 494,701.73DRANCO 4,694,301.50 2,816,580.90 45,065.29 9,388,603.00 5,633,161.80 90,130.59 46,943,015.00 28,165,809.00 450,652.94KompoGAS 4,588,415.00 2,753,049.00 44,048.78 9,176,830.00 5,506,098.00 88,097.57 45,884,150.00 27,530,490.00 440,487.84Valorga 4,023,687.00 2,414,212.20 38,627.40 8,047,374.00 4,828,424.40 77,254.79 40,236,870.00 24,142,122.00 386,273.95BTA 4,235,460.00 2,541,276.00 40,660.42 8,470,920.00 5,082,552.00 81,320.83 42,354,600.00 25,412,760.00 406,604.16
AssumptionsCompression Market $ per MMBTU $ per kWh
LNG 50psi Vehicle Fuel 4.69 0.0160
CNG 5,000psiVehicle Fuel/gas grid 4.69 0.01600
EISENMANN AD SYSTEMProposed System
04/18/23
Proposed System: Eisenmann High Solids AD
Source: http://www.eisenmann.us.com/eisenmann-high-solids-ad-system/
Eisenmann High Solids AD System (cont’d)
Benefits of the Eisenmann Biogas Plant•Continuously mixed plug-flow process•Feedstock flexibility for high solids content•High biogas yield and process stability (higher revenue)•Enclosed system prevents emissions of odors•Modular design reduces costs and decreases construction time
System ComponentsHorizontal agitatorHeating elementsControl systemIntegrated safety systemsPressure tight doorsDouble –membrane gas storageScrew-press separators
SOLID AND LIQUID DIGESTATE
Other by-products
04/18/23
Other Byproducts
Additional research was conducted to assess the types of use for the AD system by-products.
Solid and liquid digestate have a few market outlets that can be explored.
04/18/23
Refine Compressor Distribute
Low pressure Bio gas
Highpressure Bio gas
Market Research
04/18/23
Product- Solid Digestate
Agriculture-This would be the major market. Every year, the sales of corn and soybeans are able to reach $13 billion . The application of compost to soil can benefit the production.
Landscape Industry-The replacement of topsoil of landscape for industrial or residential clients is relatively expensive. The application of compost could improve the quality of existing soil and save cost to owners.
Nursery Industry-Using compost in nursery industry could benefit the housing industry. However, the market depends on the local economic and demand of high-quality houses in Chicago.
Public Agencies-Based on the various purpose, the high-quality compost can be used in the areas where is connected to human and animals while low-quality compost improve the quality of land and landfill cover.
Residential-the market of residential compost is less stable. There are a lot of factor affecting the sales, including local economy, the housing industry, the culture and population.
04/18/23
Product-Liquid digestate
The major downstream markets soil conditioner or fertilizer in gardens urban farms and turf high-quality fertilizer (with further processing)
Nutrition information of digestate made only from food and slaughterhouse waste.
Nitrogen(kg N/M3 )
Phosphate(kgP2O5/M3)
Potash(kgK2/M3)
Digestate (Liquid) 6.0 0.8 1.5PROS: Rich in nitrogen, especially available nitrogen; some digestate has Phosphorous and Potassium; source of organic matter; inexpensive
CONS: Plants may not deliver nutrients beyond certain distance; regulations can be strict regarding application rate and method; restrictions on grazing following application
04/18/23
Environmental Regulations
Storage All the site or facility used for the composting of food scrap, livestock waste, crop residue, uncont
aminated wood waste, or paper waste, including, but not limited to, corrugated paper or cardboard should meet all of the requirements under Title 35 Sections 807 & 830-832 of Illinois
Administrative Code
Transportation• The facility should be located at
least 1/8 mile from the nearest
residence in Brownsville.
• The site should be close to
feedstock participants in order to
reduce transportation cost
OPPORTUNITIESConclusions
04/18/23
04/18/23
Conclusions
Type of AD: Eisenmann SystemBiogas use for maximum revenue:
electricity generation using CHP technology
Solid digestate use: mixed as compost amendment
Liquid digestate use: fertilizer
04/18/23
Further Directions
Identify a suitable site (needs to be 1-2 acres in addition to composting facility)
Request vendor quotes for exact componentsIdentify the exact nature and amount of
feedstockDetail out systems such as transportation,
packaging, bags, compost dryer, control lab etc.
Work with IL state representatives/lobbyists on HB2335, and SB850 to ease permitting
Identify grants and investors to fund the project
QUESTIONS?Thank you!
04/18/23
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