Salient Features of Sugar Industry in Mauritius

Sugar industry has always occupied a prominent position in the Mauritian economy since the introduction of sugarcane around three centuries ago. Mauritius has been a world pioneer in establishing sales of bagasse-based energy to the public grid, and is currently viewed as a model for other sugarcane producing countries, especially the developing ones.

Sugar factories in Mauritius produce about 600,000 tons of sugar from around 5.8 million tons of sugarcane which is cultivated on an agricultural area of about 72,000 hectares. Of the total sugarcane production, around 35 percent is contributed by nearly 30,000 small growers. There are more than 11 sugar factories presently operating in Mauritius having crushing capacities ranging from 75 to 310 tons cane per hour.

During the sugar extraction process, about 1.8 million tons of Bagasse is produced as a by-product, or about one third of the sugarcane weight. Traditionally, 50 percent of the dry matter is harvested as cane stalk to recover the sugar with the fibrous fraction, i.e. Bagasse being burned to power the process in cogeneration plant. Most factories in Mauritius have been upgraded and now export electricity to the grid during crop season, with some using coal to extend production during the intercrop season.

Surplus electricity is generated in almost all the sugar mills. The total installed capacity within the sugar industry is 243 MW out of which 140 MW is from firm power producers. Around 1.6 – 1.8 million tons of bagasse (wet basis) is generated on an annually renewable basis and an average of around 60 kWh per ton sugarcane is generated for the grid throughout the island.

The surplus exportable electricity in Mauritian power plants has been based on a fibre content ranging from 13- 16% of sugarcane, 48% moisture content in Bagasse, process steam consumption of 350–450 kg steam per ton sugarcane and a power consumption of 27-32 kWh per ton sugarcane.

In Mauritius, the sugarcane industry is gradually increasing its competitiveness in electricity generation. It has revamped its boiler houses by installing high pressure boilers and condensing extraction steam turbine. All the power plants are privately owned, and the programme has been a landmark to show how all the stakeholders (government, corporate and small planters) can co-operate. The approach is being recommended to other sugarcane producing countries worldwide to harness the untapped renewable energy potential of biomass wastes from the sugar industry.

Biomass Gasification Process

Biomass gasification involves burning of biomass in a limited supply of air to give a combustible gas consisting of carbon monoxide, carbon dioxide, hydrogen, methane, water, nitrogen, along with contaminants like small char particles, ash and tars. The gas is cleaned to make it suitable for use in boilers, engines and turbines to produce heat and power (CHP).

Biomass gasification provides a means of deriving more diverse forms of energy from the thermochemical conversion of biomass than conventional combustion. The basic gasification process involves devolatization, combustion and reduction.

During devolatization, methane and other hydrocarbons are produced from the biomass by the action of heat which leaves a reactive char.

During combustion, the volatiles and char are partially burned in air or oxygen to generate heat and carbon dioxide. In the reduction phase, carbon dioxide absorbs heat and reacts with the remaining char to produce carbon monoxide (producer gas). The presence of water vapour in a gasifier results in the production of hydrogen as a secondary fuel component.

There are two main types of gasifier that can be used to carry out this conversion, fixed bed gasifiers and fluidized bed gasifiers. The conversion of biomass into a combustible gas involves a two-stage process. The first, which is called pyrolysis, takes place below 600°C, when volatile components contained within the biomass are released. These may include organic compounds, hydrogen, carbon monoxide, tars and water vapour.

Pyrolysis leaves a solid residue called char. In the second stage of the gasification process, this char is reacted with steam or burnt in a restricted quantity of air or oxygen to produce further combustible gas. Depending on the precise design of gasifier chosen, the product gas may have a heating value of 6 – 19 MJ/Nm3.

Layout of a Typical Biomass Gasification Plant

The products of gasification are a mixture of carbon monoxide, carbon dioxide, methane, hydrogen and various hydrocarbons, which can then be used directly in gas turbines, and boilers, or used as precursors for synthesising a wide range of other chemicals.

In addition there are a number of methods that can be used to produce higher quality product gases, including indirect heating, oxygen blowing, and pressurisation. After appropriate treatment, the resulting gases can be burned directly for cooking or heat supply, or used in secondary conversion devices, such as internal combustion engines or gas turbines, for producing electricity or shaft power (where it also has the potential for CHP applications).

 

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Bagasse-Based Cogeneration in Pakistan: Challenges and Opportunities

Considering the fact that Pakistan is among the world’s top-10 sugarcane producers, the potential of generating electricity from bagasse is huge.  Almost all the sugar mills in Pakistan have in-house plants for cogeneration but they are inefficient in the consumption of bagasse. If instead, high pressure boilers are installed then the production capacity can be significantly improved with more efficient utilization of bagasse.

However, due to several reasons; mostly due to financing issues, the sugar mill owners were not able to set up these plants. Only recently, after financial incentives have been offered and a tariff rate agreed upon between the government and mill owners, are these projects moving ahead.

The sugar mill owners are more than willing to supply excess electricity generated form the in-house power plants to the national grid but were not able to before, because they couldn’t reach an agreement with the government over tariff. The demand for higher tariff was justified because of large investments in setting up new boilers. It would also have saved precious foreign exchange which is spent on imported oil.

By estimating the CDM potential of cogeneration (or CHP) projects based on biofuels, getting financing for these projects would be easier. Renewable energy projects can be developed through Carbon Development Mechanism or any other carbon credit scheme for additional revenue.

Since bagasse is a clean fuel which emits very little carbon emissions it can be financed through Carbon Development Mechanism. One of the reasons high cogeneration power plants are difficult to implement is because of the high amount of costs associated. The payback period for the power plants is unknown which makes the investors reluctant to invest in the high cogeneration project. CDM financing can help improve the rate of return of the project.

Bagasse power plants generate Carbon Emission Reductions in 2 ways; one by replacing electricity produced from fossil fuels.  Secondly if not used as a fuel, it would be otherwise disposed off in an unsafe manner and the methane emissions present in biomass would pollute the environment far more than CO2 does.

Currently there are around 83 sugar mills in Pakistan producing about 3.5 million metric tons of sugar per annum with total crushing capacity 597900 TCD, which can produce approximately 3000 MW during crop season Although it may seem far-fetched at the moment, if the government starts to give more attention to  sugar industry biomass rather than coal, Pakistan can fulfill its energy needs without negative repercussions or damage to the environment.

However some sugar mills are opting to use coal as a secondary fuel since the crushing period of sugarcane lasts only 4 months in Pakistan. The plants would be using coal as the main fuel during the non-crushing season. The CDM effect is reduced with the use of coal. If a high cogeneration plant is using even 80% bagasse and 20% of coal then the CERs are almost nullified. If more than 20% coal is used then the CDM potential is completely lost because the emissions are increased. However some sugar mills are not moving ahead with coal as a secondary fuel because separate tariff rates have to be obtained for electricity generation if coal is being used in the mix which is not easily obtained.

Pakistan has huge untapped potential for bagasse-based power generation

One of the incentives being offered by the State Bank of Pakistan is that if a project qualifies as a renewable project it is eligible to get loan at 6% instead of 12%. However ones drawback is that, in order to qualify as a renewable project, CDM registration of a project is not taken into account.

Although Pakistan is on the right track by setting up high cogeneration power plants, the use of coal as a secondary fuel remains debatable.  The issue that remains to be addressed is that with such huge amounts of investment on these plants, how to use these plants efficiently during non-crushing period when bagasse is not available. It seems almost counter-productive to use coal on plants which are supposed to be based on biofuels.

Conclusion

With the demand for energy in Pakistan growing, the country is finally exploring alternatives to expand its power production. Pakistan has to rely largely on fossils for their energy needs since electricity generation from biomass energy sources is considered to be an expensive option despite abundance of natural resources. However by focusing on growing its alternate energy options such as bagasse-based cogeneration, the country will not only mitigate climate change but also tap the unharnessed energy potential of sugar industry biomass.

Summary of Biomass Combustion Technologies

Direct combustion is the best established and most commonly used technology for converting biomass to heat. During combustion, biomass fuel is burnt in excess air to produce heat. The first stage of combustion involves the evolution of combustible vapours from the biomass, which burn as flames. The residual material, in the form of charcoal, is burnt in a forced air supply to give more heat. The hot combustion gases are sometimes used directly for product drying, but more usually they are passed through a heat exchanger to produce hot air, hot water or steam.

The combustion efficiency depends primarily on good contact between the oxygen in the air and the biomass fuel. The main products of efficient biomass combustion are carbon dioxide and water vapor, however tars, smoke and alkaline ash particles are also emitted. Minimization of these emissions and accommodation of their possible effects are important concerns in the design of environmentally acceptable biomass combustion systems.

Biomass combustion systems, based on a range of furnace designs, can be very efficient at producing hot gases, hot air, hot water or steam, typically recovering 65-90% of the energy contained in the fuel. Lower efficiencies are generally associated with wetter fuels. To cope with a diversity of fuel characteristics and combustion requirements, a number of designs of combustion furnaces or combustors are routinely utilized around the world

Underfeed Stokers

Biomass is fed into the combustion zone from underneath a firing grate. These stoker designs are only suitable for small scale systems up to a nominal boiler capacity of 6 MWth and for biomass fuels with low ash content, such as wood chips and sawdust. High ash content fuels such as bark, straw and cereals need more efficient ash removal systems. Sintered or molten ash particles covering the upper surface of the fuel bed can cause problems in underfeed stokers due to unstable combustion conditions when the fuel and the air are breaking through the ash covered surface.

Grate Stokers

The most common type of biomass boiler is based on a grate to support a bed of fuel and to mix a controlled amount of combustion air, which often enters from beneath the grate. Biomass fuel is added at one end of the grate and is burned in a fuel bed which moves progressively down the grate, either via gravity or with mechanical assistance, to an ash removal system at the other end. In more sophisticated designs this allows the overall combustion process to be separated into its three main activities:

  • Initial fuel drying
  • Ignition and combustion of volatile constituents
  • Burning out of the char.

Grate stokers are well proven and reliable and can tolerate wide variations in fuel quality (i.e. variations in moisture content and particle size) as well as fuels with high ash content. They are also controllable and efficient.

Fluidized Bed Boilers

The basis for a fluidized bed combustion system is a bed of an inert mineral such as sand or limestone through which air is blown from below. The air is pumped through the bed in sufficient volume and at a high enough pressure to entrain the small particles of the bed material so that they behave much like a fluid.

The combustion chamber of a fluidized bed plant is shaped so that above a certain height the air velocity drops below that necessary to entrain the particles. This helps retain the bulk of the entrained bed material towards the bottom of the chamber. Once the bed becomes hot, combustible material introduced into it will burn, generating heat as in a more conventional furnace. The proportion of combustible material such as biomass within the bed is normally only around 5%. The primary driving force for development of fluidized bed combustion is reduced SO2 and NOx emissions from coal combustion.

Bubbling fluidized bed (BFB) combustors are of interest for plants with a nominal boiler capacity greater than 10 MWth. Circulating fluidized bed (CFB) combustors are more suitable for plants larger than 30 MWth. The minimum plant size below which CFB and BFB technologies are not economically competitive is considered to be around 5-10 MWe.

Use of Palm Kernel Shells in Circulating Fluidized Bed Power Plants

Palm kernel shells are widely used in fluidized bed combustion-based power plants in Japan and South Korea. The key advantages of fluidized bed combustion (FBC) technology are higher fuel flexibility, high efficiency and relatively low combustion temperature. FBC technology, which can either be bubbling fluidized bed (BFB) or circulating fluidized bed (CFB), is suitable for plant capacities above 20 MW. Palm kernel shells (PKS) is more suitable for CFB-based power plant because its size is less than 4 cm.

With relatively low operating temperature of around 650 – 900 oC, the ash problem can be minimized. Certain biomass fuels have high ash levels and ash-forming materials that can potentially damage these generating units. In addition, the fuel cleanliness factor is also important as certain impurities, such as metals, can block the air pores on the perforated plate of FBC unit. It is to be noted that air, especially oxygen, is essential for the biomass combustion process and for keeping the fuel bed in fluidized condition.

The requirements for clean fuel must be met by the provider or seller of the biomass fuel. Usually the purchasers require an acceptable amount of impurities (contaminants) of less than 1%. Cleaning of PKS is done by sifting (screening) which may either be manual or mechanical.

In addition to PKS, biomass pellets from agricultural wastes or agro-industrial wastes, such as EFB pellets which have a high ash content and low melting point, can also be used in CFB-based power plants. More specifically, CFBs are more efficient and emit less flue gas than BFBs.

The disadvantages of CFB power plant is the high concentration of the flue gas which demands high degree of efficiency of the dust precipitator and the boiler cleaning system. In addition, the bed material is lost alongwith ash and has to be replenished regularly.

A large-scale biomass power plant in Japan

The commonly used bed materials are silica sand and dolomite. To reduce operating costs, bed material is usually reused after separation of ash. The technique is that the ash mixture is separated from a large size material with fine particles and silica sand in a water classifier. Next the fine material is returned to the bed.

Currently power plants in Japan that have an efficiency of more than 41% are only based on ultra supercritical pulverized coal. Modification of power plants can also be done to improve the efficiency, which require more investments. The existing CFB power plants are driving up the need to use more and more PKS in Japan for biomass power generation without significant plant modifications.

Combined Heat and Power Systems in Biomass Industry

Combined Heat and Power (CHP) is the simultaneous generation of multiple forms of useful energy (usually mechanical and thermal) in a single, integrated system. In conventional electricity generation systems, about 35% of the energy potential contained in the fuel is converted on average into electricity, whilst the rest is lost as waste heat. CHP systems use both electricity and heat and therefore can achieve an efficiency of up to 90%.

CHP technologies are well suited for sustainable development projects because they are socio-economically attractive and technologically mature and reliable. In developing countries, cogeneration can easily be integrated in many industries, especially agriculture and food-processing, taking advantage of the biomass residues of the production process. This has the dual benefits of lowering fuel costs and solving waste disposal issues.

CHP systems consist of a number of individual components—prime mover (heat engine), generator, heat recovery, and electrical interconnection—configured into an integrated whole. Prime movers for CHP units include reciprocating engines, combustion or gas turbines, steam turbines, microturbines, and fuel cells. A typical CHP system provides:

  • Distributed generation of electrical and/or mechanical power.
  • Waste-heat recovery for heating, cooling, or process applications.
  • Seamless system integration for a variety of technologies, thermal applications, and fuel types.

The success of any biomass-fuelled CHP project is heavily dependent on the availability of a suitable biomass feedstock freely available in urban and rural areas.

Rural Resources Urban Resources
Forest residues Urban wood waste
Wood wastes Municipal solid wastes
Crop residues Agro-industrial wastes
Energy crops Food processing residues
Animal manure Sewage

Technology Options

Reciprocating or internal combustion engines (ICEs) are among the most widely used prime movers to power small electricity generators. Advantages include large variations in the size range available, fast start-up, good efficiencies under partial load efficiency, reliability, and long life.

Steam turbines are the most commonly employed prime movers for large power outputs. Steam at lower pressure is extracted from the steam turbine and used directly or is converted to other forms of thermal energy. System efficiencies can vary between 15 and 35% depending on the steam parameters.

Co-firing of biomass with coal and other fossil fuels can provide a short-term, low-risk, low-cost option for producing renewable energy while simultaneously reducing the use of fossil fuels. Biomass can typically provide between 3 and 15 percent of the input energy into the power plant. Most forms of biomass are suitable for co-firing.

Steam engines are also proven technology but suited mainly for constant speed operation in industrial environments. Steam engines are available in different sizes ranging from a few kW to more than 1 MWe.

A gas turbine system requires landfill gas, biogas, or a biomass gasifier to produce the gas for the turbine. This biogas must be carefully filtered of particulate matter to avoid damaging the blades of the gas turbine.  

Stirling engines utilize any source of heat provided that it is of sufficiently high temperature. A wide variety of heat sources can be used but the Stirling engine is particularly well-suited to biomass fuels. Stirling engines are available in the 0.5 to 150 kWe range and a number of companies are working on its further development.

A micro-turbine recovers part of the exhaust heat for preheating the combustion air and hence increases overall efficiency to around 20-30%. Several competing manufacturers are developing units in the 25-250kWe range. Advantages of micro-turbines include compact and light weight design, a fairly wide size range due to modularity, and low noise levels.

Fuel cells are electrochemical devices in which hydrogen-rich fuel produces heat and power. Hydrogen can be produced from a wide range of renewable and non-renewable sources. A future high temperature fuel cell burning biomass might be able to achieve greater than 50% efficiency.

A Glance at Woody Biomass Resources

Woody biomass resources range from corn kernels to corn stalks, from soybean and canola oils to animal fats, from prairie grasses to hardwoods, and even include algae. Woody biomass may be used for energy production at different scales, including large-scale power generation, CHP, or small-scale thermal heating projects. Some of the major sources of woody biomass are being discussed in the following paragraphs:

Pulp and Paper Industry Residues

The largest source of energy from wood is the waste product from the pulp and paper industry called black liquor. Logging and processing operations generate vast amounts of biomass residues. Wood processing produces sawdust and a collection of bark, branches and leaves/needles. A paper mill, which consumes vast amount of electricity, utilizes the pulp residues to create energy for in-house usage.

Forest Residues

Forest harvesting is a major source of biomass for energy. Harvesting may occur as thinning in young stands, or cutting in older stands for timber or pulp that also yields tops and branches usable for bioenergy. Harvesting operations usually remove only 25 to 50 percent of the volume, leaving the residues available as biomass for energy. Stands damaged by insects, disease or fire are additional sources of biomass. Forest residues normally have low density and fuel values that keep transport costs high, and so it is economical to reduce the biomass density in the forest itself.

Agricultural or Crop Residues

Crop residues encompasses all agricultural wastes such as straw, stem, stalk, leaves, husk, shell, peel, pulp, stubble, etc. which come from cereals (rice, wheat, maize or corn, sorghum, barley, millet), cotton, groundnut, jute, legumes (tomato, bean, soy) coffee, cacao, tea, fruits (banana, mango, coco, cashew) and palm oil.

Rice produces both straw and rice husks at the processing plant which can be conveniently and easily converted into energy. Significant quantities of biomass remain in the fields in the form of cob when maize is harvested which can be converted into energy. Sugar cane harvesting leads to harvest residues in the fields while processing produces fibrous bagasse, both of which are good sources of energy.

Energy Crops

Dedicated energy crops are another source of woody biomass for energy. These crops are fast-growing plants, trees or other herbaceous biomass which are harvested specifically for energy production. Rapidly-growing, pest-tolerant, site and soil-specific crops have been identified by making use of bioengineering. For example, operational yield in the northern hemisphere is 10-15 tonnes/ha annually. A typical 20 MW steam cycle power station using energy crops would require a land area of around 8,000 ha to supply energy on rotation.

Herbaceous energy crops are harvested annually after taking two to three years to reach full productivity. These include grasses such as switchgrass, elephant grass, bamboo, sweet sorghum, wheatgrass etc. Short rotation woody crops are fast growing hardwood trees harvested within five to eight years after planting. These include poplar, willow, silver maple, cottonwood, green ash, black walnut, sweetgum, and sycamore.

Industrial crops are grown to produce specific industrial chemicals or materials, e.g. kenaf and straws for fiber, and castor for ricinoleic acid. Agricultural crops include cornstarch and corn oil soybean oil and meal wheat starch, other vegetable oils etc. Aquatic resources such as algae, giant kelp, seaweed, and microflora also contribute to bioenergy feedstock.

Urban Wood Wastes

Such waste consists of lawn and tree trimmings, whole tree trunks, wood pallets and any other construction and demolition wastes made from lumber. The rejected woody material can be collected after a construction or demolition project and turned into mulch, compost or used to fuel bioenergy plants.

Biomass Resources in Malaysia

Malaysia is gifted with conventional energy resources such as oil and gas as well as renewables like hydro, biomass and solar energy. As far as biomass resources in Malaysia are concerned, Malaysia has tremendous agricultural biomass and wood waste resources available for immediate exploitation. This energy potential of biomass resource is yet to be exploited properly in the country.

Taking into account the growing energy consumption and domestic energy supply constraints, Malaysia has set sustainable development and diversification of energy sources, as the economy’s main energy policy goals. The Five-Fuel Strategy recognises renewable energy resources as the economy’s fifth fuel after oil, coal, natural gas and hydro. Being a major agricultural commodity producer in the region Malaysia is well positioned amongst the ASEAN countries to promote the use of biomass as a source of renewable energy.

Major Biomass Resources

Palm Oil Biomass

Malaysia is the world’s leading exporter of palm oil, exporting more than 19.9 million tonnes of palm oil in 2017. The extraction of palm oil from palm fruits results in a large quantity of waste in the form of palm kernel shells, empty fruit bunches and mesocarp fibres. In 2011, more than 80 million tons of oil palm biomass was generated across the country.

13MW biomass power plant at a palm oil mill in Sandakan, Sabah (Malaysia)

Processing crude palm oil generates a foul-smelling effluent, called Palm Oil Mill Effluent or POME, which when treated using anaerobic processes, releases biogas. Around 58 million tons of POME is produced in Malaysia annually, which has the potential to produce an estimated 15 billion m3 of biogas.

Rice Husk

Rice husk is another important agricultural biomass resource in Malaysia with very good energy potential for biomass cogeneration. An example of its attractive energy potential is biomass power plant in the state of Perlis which uses rice husk as the main source of fuel and generates 10 MW power to meet the requirements of 30,000 households.

Municipal Solid Wastes

The per capita generation of solid waste in Malaysia varies from 0.45 to 1.44kg/day depending on the economic status of an area. Malaysian solid wastes contain very high organic waste and consequently high moisture content and bulk density of above 200kg/m3. The high rate of population growth is the country has resulted in rapid increase in solid waste generation which is usually dumped in landfills.

Conclusion

Biomass resources have long been identified as sustainable source of renewable energy particularly in countries where there is abundant agricultural activities. Intensive use of biomass as renewable energy source in Malaysia could reduce dependency on fossil fuels and significant advantage lies in reduction of net carbon dioxide emissions to atmosphere leading to less greenhouse effect. However, increased competitiveness will require large-scale investment and advances in technologies for converting this biomass to energy efficiently and economically.

Biomass Cogeneration Systems

Biomass fuels are typically used most efficiently and beneficially when generating both power and heat through biomass cogeneration systems (also known as combined heat and power or CHP system). Biomass conversion technologies transform a variety of wastes into heat, electricity and biofuels by employing a host of strategies. Conversion routes are generally thermochemical or biochemical, but may also include chemical and physical.

The simplest way is to burn the biomass in a furnace, exploiting the heat generated to produce steam in a boiler, which is then used to drive a steam turbine. Advanced biomass conversion technologies include biomass integrated gasification combined cycle (BIGCC) systems, cofiring (with coal or gas), pyrolysis and second generation biofuels.

Biomass Cogeneration Systems

A typical biomass cogeneration (or biomass cogen) system provides:

  • Distributed generation of electrical and/or mechanical power.
  • Waste-heat recovery for heating, cooling, or process applications.
  • Seamless system integration for a variety of technologies, thermal applications, and fuel types into existing building infrastructure.

Biomass cogeneration systems consist of a number of individual components—prime mover (heat engine), generator, heat recovery, and electrical interconnection—configured into an integrated whole. The type of equipment that drives the overall system (i.e., the prime mover) typically identifies the CHP unit.

Prime Movers

Prime movers for biomass cogeneration units include reciprocating engines, combustion or gas turbines, steam turbines, microturbines, and fuel cells. These prime movers are capable of burning a variety of fuels, including natural gas, coal, oil, and alternative fuels to produce shaft power or mechanical energy.

Key Components

A biomass-fueled cogeneration facility is an integrated power system comprised of three major components:

  • Biomass receiving and feedstock preparation.
  • Energy conversion – Conversion of the biomass into steam for direct combustion systems or into biogas for the gasification systems.
  • Power and heat production – Conversion of the steam or syngas or biogas into electric power and process steam or hot water

Feedstock for Biomass Cogeneration Plants

The lowest cost forms of biomass for cogeneration plants are residues. Residues are the organic byproducts of food, fiber, and forest production, such as sawdust, rice husks, wheat straw, corn stalks, and sugarcane bagasse. Forest residues and wood wastes represent a large potential resource for energy production and include forest residues, forest thinnings, and primary mill residues.

combined-heat-and-power

Energy crops are perennial grasses and trees grown through traditional agricultural practices that are produced primarily to be used as feedstocks for energy generation, e.g. hybrid poplars, hybrid willows, and switchgrass. Animal manure can be digested anaerobically to produce biogas in large agricultural farms and dairies.

To turn a biomass resource into productive heat and/or electricity requires a number of steps and considerations, most notably evaluating the availability of suitable biomass resources; determining the economics of collection, storage, and transportation; and evaluating available technology options for converting biomass into useful heat or electricity.

Biogas-to-Biomethane Conversion Technologies

biogas-biomethaneRaw biogas contains approximately 30-45% of CO2, and some H2S and other compounds that have to be removed prior to utilization as natural gas, CNG or LNG replacement. Removing these components can be performed by several biogas upgrading techniques. Each process has its own advantages and disadvantages, depending on the biogas origin, composition and geographical orientation of the plant. The biogas-to-biomethane conversion technologies taken into account are pressurized water scrubbing (PWS), catalytic absorption/amine wash (CA), pressure swing absorption (PSA), highly selective membrane separation (MS) and cryogenic liquefaction (CL) which are the most common used biogas cleanup techniques.

The Table below shows a comparison of performance for these techniques at 8 bar (grid) injection.

Table:  Comparison of performance for various upgrading techniques (result at 8 bar) (Robert Lems, 2010) , (Lems R., 2012)

  PWS CA PSA MS CL Unit
Produced gas quality*2 98 99 97-99 99 99.5 CH4%
Methane slip 1 0.1-0.2 1-3 0.3-0.5 0.5 %
Electrical use 0.23-0.25 0.15-0.18 0.25 0.21-0.24 0.35 kWh/Nm3 feed
Thermal energy use 0,82-1.3 kWth/Nm3 prod.
Reliability / up time 96 94 94 98 94 %
Turn down ratio 50-100 50-100 85-100 0-100 75-100 %
CAPEX Medium Medium Medium Low High  
Operation cost Low Medium Medium Low High  
Foot print Large Large Medium Small Large  
Maintenance needed Medium Medium+ Medium+ Low High  
Ease of operation Medium Medium+ Medium Easy Complex  
Consumables &

waste streams

AC*3/Water AC*3/amines AC*3/ absorbents AC*3/None AC*3/None  
References Many Many Medium Medium Very few  

*2 If no oxygen of nitrogen is present in the raw biogas

*3 Activated carbon (AC) consumption is depending on the presence of certain pollutants (trace components) within the raw biogas.

From the above Table, it can be concluded that the differences between technologies with respect to performance seem to be relatively small. However, some “soft factors” can have a significant impact on technology selection. For example, water scrubber technology is a broadly applied technology. The requirement for clean process water, to make up for discharge and condensation, could be a challenging constraint for remote locations.

Moreover, PWS systems are prone to biological contamination (resulting in clogged packing media and foaming), especially when operated at elevated temperatures. Without additional preventative measures this will result in an increase of operational issues and downtime.

Amine scrubbers are a good choice when surplus heat is available for the regeneration of the washing liquid. The transport and discharge of this washing liquid could however be a burden, as well as the added complexity of operation. With respect to cryogenic Liquefaction (CL) one may conclude that, this technology has a questionable track-record, is highly complex, hard to operate, and should therefore not be selected for small-medium scale applications.

Both PSA and MS provide a “dry” system, both technologies operate without the requirement for a solvent/washing liquid, which significantly simplifies operation and maintenance. Distinctive factor between these technologies is that the membrane based system operates in a continuous mode, while the PSA technology is based on columns filled with absorption materials which operate in a rotating/non-continuous mode.

Moreover, the membrane based system has a more favourable methane slip, energy consumption and turndown ratio. The biggest advantage over PSA however, is that membrane systems do not require any transport of absorbents, its ease of operation and superior up-time.

Main disadvantage of membrane systems are that they are sensitive to pollution by organic compounds, which can decrease efficiency. However, by applying a proper pre-treatment (generally based on activated carbon and condensation) in which these compounds are eliminated, this disadvantage can be relatively easy nullified.

Based on membrane technology, DMT Environmental Technology, developed the Carborex ®MS. A cost-effective plug and play, containerized (and therefore), easy to build in remote locations) biogas upgrading system. The Carborex ®MS membrane system has relatively little mechanical moving components (compared to other upgrading technologies) and therefore, ensures stability of biomethane production, and consequently, the viability of the biogas plant operation.

Moreover, its design for ease of operation and robustness makes this technological platform perfectly suitable for operation at locations with limited experience and expertise on handling of biogas plants.

Impression of a membrane system; Carborex ®MS – by courtesy of DMT

Impression of a membrane system; Carborex ®MS – by courtesy of DMT

Conclusions

Capture of biogas through application of closed ponds or AD’s is not only a necessity for mitigation of greenhouse gas emissions, it is also a method of optimizing liquid waste treatment and methane recovery. Billions of cubic meters of biomethane can be produced on a yearly basis, facilitating a significant reduction of fossil fuel dependency.

Moreover, upgrading of raw biogas-to-biomethane (grid, CNG or LNG quality) provides additional utilization routes that have the extra advantage to be independent of existing infrastructure. To sum up, membrane based technology is the best way forward due to its ease of operation, robustness and the high quality of the end-products.

References

  • Lems R., D. E. (2012). Next generation biogas upgrading using high selective gas separation membranes. 17th European Biosolids Organic Resources Conference. Leeds: Aqua Enviro Technology .
  • Robert Lems, E. D. (2010). Making pressurized water scrubbing the ultimate biogas upgrading technology with the DMT TS-PWS® system. Energy from Biomass and Waste UK . London: EBW-UK .

Co-Authors: H. Dekker and E.H.M. Dirkse (DMT Environmental Technology)

Note: This is the final article in the special series on ‘Sustainable Utilization of POME-based Biomethane’ by Langerak et al of DMT Environmental Technology (Holland). The first two articles can be viewed at these links

http://www.bioenergyconsult.com/biomethane-utilization/

http://www.bioenergyconsult.com/pome-biogas/