Low Carbon Energy Business Initiatives Vishwas P Pitke, General - - PowerPoint PPT Presentation

Low Carbon Energy Business Initiatives

Vishwas P Pitke, General Manager (Special Projects), Fleetguard Filters Private Ltd., ‘Kirloskar House’, 100, Anand Park, Aundh, Pune-411 007, Maharashtra, India

• Tel- +91 20 25883903

Fax- +91 20 25887428 / 25884557 Mobile- +91 9850995968 , 9011092781 v.p.pitke@fleetguard-filtrum.com

Philosophy

• Ecosystem is fragile. It needs protection
• Environment is the matter of everyone's concern
• Reclaiming environment is the top priority
• Waste is hazardous material which degrades environment but

can be utilized for generating resources and reclaiming environment

• Sustainable resource generation is possible from waste
• Mission should be launched for protecting the environment
• Public awareness and active participation, technology are the

key requirements to take this mission on war footing

• This war can be won with committed efforts

Benefits accrued……

• Waste disposal gets profit centre oriented activity
• Renewable Resource generation out of waste
• Carbon credit revenue can be factored in
• Gets legal & environmental compliance
• Employment generation among lower strata
• Savings over fossil fuels forever
• Decentralized power generation near load centre
• Improved health & hygiene standards
• Organic manure generation for sustainable agriculture
• Fiscal & financial benefits available

Long Term Business Prospects…

• Renewable energy is going to get more & more focus
• Environmental awareness & pollution control

measures are going to be more and more stringent

• Society is going to ask for improved standards of

health and hygiene always

• Waste disposal is becoming profit centre activity
• Fiscal and financial incentives are available
• Waste generation is forever increasing phenomenon
• Polluters, investors/financers, statutory bodies

wants reliable technology suppliers/contractors

Future Fuel Resources…

• Focus on wastes as misplaced resource
• Harness agro fuels as renewable energy

resource

New Business Opportunities…

• Anaerobic Bio digestion process

Biodegradable residues as resource…..

• Any type of organically biodegradable solid or liquid

waste can be used as resource

• Vegetable wastes, liquid (effluents) and solid wastes

generated by agro processing and food processing industries, Municipal Solid Waste (MSW), liquid and solid wastes which are organic in nature are best residues

• Above residues after subjecting to anaerobic bio

digestion process through methanogenic bacteria releases biogas

• This biogas can be used as fuel for thermal

applications and/or power generation

Biodigestion process…….

• Biodegradable effluents, vegetable/fruit wastes, solid waste ,etc
• Pretreatment of waste- to adjust pH, temperature of effluent and to reduce size

and segregate solid wastes

• Addition of water to prepare preconditioned slurry/feedstock most suitable for

biological degradation

• Charging/feeding the slurry/feedstock in bioreactor loaded with methanogenic

bacterial culture for biological degradation of slurry

• Biogas generation after biological reaction inside bioreactor and treated effluent
• r treated solids as residues/by products
• Biogas extraction and cleaning through foam trap, sediment traps to remove

particulate matter and foam

• Removal of Hydrogen Sulfide (H2S) through H2S scrubbers
• Removal of CO2 through CO2 scrubbers (If required)
• Feeding cleaned biogas through gas blowers to genset
• Biogas based power generation through genset
• Waste heat recovery for chilling of biogas or other applications

Biogas as fuel……

• Biogas is mixture of gasses
• Chemical composition (Volume / Volume)

CH4 - 50 to 70 % CO2 - 28 to 45 % H2S - 1 to 5 % Saturated with moisture Calorific value of 5300 to 5500 Kcal/M3 For Genset applications, CH4 should be at least 70% and H2S should be less than 700 PPM

Spill Over Technology Basket……

Compressed Natural gas from Biogas Waste Heat Recovery (WHR) systems for; * Power generation * Steam generation * Hot water generation * Cold storage * Ice making plant * Air Conditioning Power generation through Pressure Reducing Valve (PRV) steam with induction generator Energy audits

Small to medium scale Solid Waste to Biogas Projects 1 to 5 Tons Per Day (TPD) Modular form

Small Biogas Plants (SBP)- Approx. Market size

• Dairy - 72 MW
• Food & Fruit - 99 MW
• Poultry - 120 MW
• Solid Waste - 300 MW
• Animal farming - 1000 MW
• Misc. Biowaste
• 500 MW

Primary Market Segment

• Dairy farms
• Goshalas
• Canteen and food waste
• Food and fruit processing units
• Municipal Solid waste (MSW)

Small Biogas to Power-Fiscal and Financial incentives

• Biodigestion projects-Waste to biogas

Only 100% depreciation benefit Income tax exemption

• Waste to Biogas and Biogas to Power

Rs.40,000/KW capital subsidy 100% depreciation benefit Income tax exemption Max.5% customs duty on imported equipments

• Waste to Biogas and Biogas compression for CNG

Capital Investment subsidy 100% depreciation benefit Income tax exemption

Small Biogas Plant- Process Flow Sheet

Typical Plant Lay out…….

MSW/Canteen waste to Biogas Plant- Work in Progress

5 kW Biogas genset installation

Biogas filtration and bottling plant

11

Fig.1: Experimental setup for biogas purification and bottling

5 1 3 2 4 6 7 1-Biogas plant 2-Ball valve 3-Water remover 4-Receiver mounted compressor 5-Pressure gauge 6-Gas Storage Vessel 7-Rotameter 8-Supporting stand 9-Reshching rings 10-Scrubber 11-Safety valve 12-Water sprayer 13-Flange 14-View glass 15-Water outlet 16-Water pump 17-Gas filter 18-Pressure reducer 19-Three stage gas compressor 20-CNG Cylinder 10 9 12 8 15 16 19 18 13 17 14

NOT TO SCALE

20

Large Scale Biogas Projects

Biogas-Market Size

12068

Total

6569 Biogas & Producer Gas Animal farming 12 3000 Biogas & Producer Gas

• Misc. biomass, etc.

11 600 Biogas & Producer Gas Solid waste 10 354 Biogas Paper & Pulp 9 288 Biogas Tannery 8 245 Producer gas Willow dust 7 197 Biogas Sugar Factory 6 155 Biogas Sewage treatment 5 120 Biogas Poultry 4 99 Biogas Food and Fruit 3 72 Biogas Dairy 2 369 Biogas Distillery 1

MW Fuel Available Industry

• Sr. No.

Industrial market potential--- waste to energy…

MW Potential - 4952MW

MSW 18% Distillery Waste 6% Processing based Agro residue 38% 10% of field based agro residue 28% Pressmud 4% Food & Fruit w aste 1% Sew age 2% Pulp & Paper, Dairy , Tannery 3%

Targeted Renewable Power Projects by MNRE for Implementation by 2008

MW Potential - 1700 MW

MSW 53% Distillery Waste 18% Pressmud 13% Pulp & Paper, Dairy , Tannery 8% Food & Fruit w aste 2% Sew age 6%

TREATMENT TECHNOLOGIES & SERVICES AVAILABLE FOR LARGE SIZE BIOGAS PLANTS-

• dairy manure
• pig manure
• chicken and poultry manure
• AD of energy crops
• AD of food residues and MSW
• AD of slaughter house waste
• AD of sewage sludge
• AD of destillery mash
• AD of waste from the food processing industry
• AD of organic polluted waste water

Biogas Plant- Cow manure

location Ludhiana/India start of operation 2003 capacity . 86.000 t/a Electric power installed 1.000 kW digester size/type 2* 5.000 m³ BIMA location Germany start of operation 2003 capacity . 40 000 t/a Electric power installed 380 kW digester size/type 3 200 m³ CSTR

Biogas Plant- Pig and Chicken Manure

location Germany start of operation 2002 Capacity pig manure 90.000 t/a Electric power installed 625 kW digester size/type 5.100 m³ CSTR location Namakkal/India start of operation 2008 Capacity chicken manure 30.000 t/a Electric power installed 1.500 kW digester size/type 2* 5.000 m³ BIMA

Biogas Plant- Food Residue & Bio waste

Location Germany start of operation 2002 capacity . 40 000 t/a Electric power installed 1.416 kW + 511 kW digester size/type 2* 2 600 m³ CSTR location Germany start of operation 2007 capacity 50 000 t/a Electric power installed 2* 1021 kW digester size/type 2* 3.500 m³ CSTR

Biogas Plant- Slaughter House Waste

location Rudram Village (Medak)/India start-up 2003 capacity . 22 000 t/a digester capacity/type 2.200 m³ BIMA Biogas generation 2.600 m³/day

Biogas Plant- Sewage Sludge

location Germany start of operation 2000 inhibitants or equiv. 50,000 digester capacity 2 * 1 500 m³ (2* 396,200) digester type BIMA

H2S Scrubber

Germany

plant data:

location Germany start-up October 2006

capacity . 40 000 t/a (88,200,000 lbm/yr) digester capacity/type 3 * 3 500 m³ CSTR (3* 924,400 gal) post-digester capacity/type 4 * 2 400 m³ MBS (4* 633,900 gal) power installed 3 * 1.021 kW

3 MW Energy Crops based Bio power

MSW to POWER

RECEPTION THERMAL PRETREATMENT DIGESTION EFFLUENT DISPOSAL GAS UTILISATION MECHANICAL PRETREATMENT

waste processing

pulper plant / multisorter / press for light fraction

• dissolving of organics
• sorting of contamination light/heavy fraction
• full automatic process
• efficiency > 90 %

.

pasteurization plant

pasteurization plant

• temperature

> 70 °C

• process time

60 min.

• full automatic process

digester

CSTR-digester

post digester

Storage of digestate

gas line – storage of digestate

• gas treatment / utilzation

biogas plants for food residues & biowaste

reference

location Germany start of operation 2002 capacity . 40.000 t/a Electric power installed 1.416 kW + 511 kW digester size/type 2* 2.600 m³ CSTR

biogas plants for food residues & biowaste

reference

location UK start of construction 20010 capacity . 160.000 t/a Electric power installed 4* 1.021 kW digester size/type 4* 4.000 m³ CSTR

Log Book – M/S Kanoria Chemicals, India…..

Anaerobic Bio digestion Technology Status

• Effluent to Biogas -Fully reliable and commercially proven
• H2S scrubbing -Fully reliable and commercially proven
• Biogas to Power -Fully reliable and commercially proven
• Solid waste to Biogas -Fully reliable and commercially proven
• MSW to Power -Fully reliable but NOT commercially

proven

• Biogas to CNG -Fully reliable and commercially proven

for 5 TPD waste processing capacity BUT not yet tried for higher quantities of waste processing capacity

Biomass Gassification Technology

Business potential – producer Gas

Processing based agro residues - 1868 MW (Rice husk, Maize cobs, Coconut shells, bagasse, etc) Field Based Agro Residues - 13843 MW (Rice straw, Wheat straw, all agro waste in field, etc.,) Willow Dust - 245 MW Food and Fruit Wastes - 50 MW

• Misc. Other - 1500 MW
• TOTAL
• 17506 MW
• Source- MNRE, Govt Of India

Biomass as Fuel……..

• Dry waste like fuel wood, agro-residues/waste from

field, bagasse, coconut shells, loose biomass like rice husk/willow dust, etc., coffee and other plantation wastes and similar biomass, which is organically non-degradable, generates producer gas as fuel, after biomass gasification process

• Producer gas can be used as fuel to generate power
• Waste residues are always available and can be

regenerated, hence this is renewable and sustainable source of power generation

Biomass Gasification Process

• Basic raw feedstock-wood, agro-waste, bagasse, etc.,
• Feedstock sizing for preparing feed of typically/approx. 5 cm size of

chips/briquettes

• Drying of prepared feed to remove moisture up to 10%
• Charging/loading of dried feedstock inside gassifier reactor
• Degradation of feedstock to generate hot producer gas as product and ash, tar as

process residues/by products

• Removal of dry particles/dust through cyclone filters
• Reduction of tar and fine particles through water scrubbers
• Chilling of gas with chilled water to remove fine particles/tar and to cool the

producer gas

• Feeding of producer gas through gas blowers at engine inlet through specially

developed carburetor

• Engine exhaust heat utilised for drying feedstock and as input to chillers. Use of

dry feedstock is extremely important to control tar and particulates

• Water treatment plant to treat waste water for recirculation

Producer Gas-Composition

• Producer gas is a mixture of gasses
• Chemical composition in general (Volume/ Volume)

CO - 20 +/- 2% H2 - 20 +/- 2% CH4 - 3 +/- 1% CO2 - 12 +/-2% O2 - 0.1% (Max) N2 - Rest All

• Composition varies drastically from feedstock to feedstock
• Calorific Value - Typically 1100 to 1200 Kcal/M3
• For Genset applications, Tar and Particulate

matter in above gas must be NIL or less than 5 PPM (?)

Impurities in Producer Gas

• Tar
• Particulates
• Dust
• Water vapor
• Oil

For Genset applications, all above impurities must be as close to NIL as possible. There is no defined industry standard for this

Biomass Gasification-Technology Status

• Not yet reliable solution for POWER

GENERATION

• Acceptable solution for replacement of

liquid/solid fossil fuel for thermal applications

• Biomass/coal are the mainly suitable input

fuels

• WORTH CONSIDERING FOR DEVELOPMENT

TO MAKE IT RELIABLE & VIABLE

Thank You !

Vishwas P Pitke, General Manager (Special Projects), Fleetguard Filters Private Ltd., ‘Kirloskar House’, 100, Anand Park, Aundh, Pune-411 007, Maharashtra, India

• Tel- +91 20 25883903

Fax- +91 20 25887428 / 25884557 Mobile- +91 9850995968 , 9011092781 v.p.pitke@fleetguard-filtrum.com