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 • or 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 1-Biogas plant 11-Safety valve 2-Ball valve 12-Water sprayer NOT TO SCALE 3-Water remover 13-Flange 11 4-Receiver mounted compressor 14-View glass 5-Pressure gauge 15-Water outlet 6-Gas Storage Vessel 16-Water pump 12 13 7-Rotameter 17-Gas filter 14 8-Supporting stand 18-Pressure reducer 9-Reshching rings 19-Three stage gas compressor 10-Scrubber 20-CNG Cylinder 10 20 9 17 8 5 2 6 7 3 1 19 16 18 4 15 Fig.1: Experimental setup for biogas purification and bottling
Large Scale Biogas Projects
Biogas-Market Size Sr. No. Industry Fuel Available MW 1 Distillery Biogas 369 2 Dairy Biogas 72 3 Food and Fruit Biogas 99 4 Poultry Biogas 120 5 Sewage treatment Biogas 155 6 Sugar Factory Biogas 197 7 Willow dust Producer gas 245 8 Tannery Biogas 288 9 Paper & Pulp Biogas 354 10 Solid waste Biogas & Producer Gas 600 11 Misc. biomass, etc. Biogas & Producer Gas 3000 12 Animal farming Biogas & Producer Gas 6569 12068 Total
Industrial market potential--- waste to energy… 10% of field based MW Potential - 4952MW agro residue 28% MSW 18% Distillery Waste Processing based Pressmud 6% Agro residue 4% Pulp & Paper, Dairy , 38% Sew age Tannery Food & Fruit w aste 2% 3% 1%
Targeted Renewable Power Projects by MNRE for Implementation by 2008 MW Potential - 1700 MW MSW 53% Distillery Waste 18% Pulp & Paper, Dairy , Pressmud Sew age Tannery Food & Fruit w aste 13% 6% 8% 2%
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 location Germany start of operation 2003 start of operation 2003 capacity . 86.000 t/a capacity . 40 000 t/a Electric power installed 1.000 kW Electric power installed 380 kW digester size/type 2* 5.000 m³ BIMA digester size/type 3 200 m³ CSTR
Biogas Plant- Pig and Chicken Manure location Namakkal/India location Germany start of operation 2008 start of operation 2002 Capacity chicken manure 30.000 t/a Capacity pig manure 90.000 t/a Electric power installed 1.500 kW Electric power installed 625 kW digester size/type 2* 5.000 m³ BIMA digester size/type 5.100 m³ CSTR
Biogas Plant- Food Residue & Bio waste Location Germany location Germany start of operation 2002 start of operation 2007 capacity . 40 000 t/a capacity 50 000 t/a Electric power installed 1.416 kW + 511 kW Electric power installed 2* 1021 kW digester size/type 2* 2 600 m³ CSTR 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
3 MW Energy Crops based Bio power capacity . 40 000 t/a plant data : (88,200,000 lbm/yr) digester capacity/type 3 * 3 500 m³ CSTR location Germany (3* 924,400 gal) start-up October 2006 post-digester capacity/type 4 * 2 400 m³ MBS (4* 633,900 gal) power installed 3 * 1.021 kW
MSW to POWER
RECEPTION MECHANICAL PRETREATMENT THERMAL PRETREATMENT DIGESTION EFFLUENT DISPOSAL GAS UTILISATION
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