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HomeMy WebLinkAboutBioFerm SOQ CITY OF HOONAH Janette Keiser J. Keiser & Associates LLC August 6, 2015 Page | 2 BIOFermTM Energy Systems www.BIOFermEnergy.com info@BIOFermEnergy.com DISCLAIMER / RESERVATION CLAUSE / COPYRIGHT This document serves the purpose of providing general information about BIOFermTM Energy Systems’ products and services; it does not serve the purpose of giving any technical advice or instructions regarding these products and service. If you have specific questions regarding our products and services, please do not hesitate to contact us. It is our wish to provide you with correct and current information. However, we do not give any guarantee for the correctness and completeness of the information. Further more, we do not accept any liability for any type of damage resulting from the use of the information published herein. Technical changes are reserved. All reproducible images and information contained in this document are protected by copyright or other commercial protective rights. All product names written in capital letters or marked in any other way in this document are trademarks. Any use and reproduction of this document or part of information is not permitted without the prior written consent of BIOFermTM Energy Systems. We reserve the right to alter performance, specification, design and change the contents of this document without prior notice. No liability arises from this. ©2015 BIOFerm™ Energy Systems USA, Inc. Page | 3 BIOFermTM Energy Systems www.BIOFermEnergy.com info@BIOFermEnergy.com TABLE OF CONTENTS Disclaimer / Reservation Clause / Copyright ................................................................................................. 2 Company Profile ............................................................................................................................................ 4 BIOFerm™ Energy Systems ..................................................................................................................... 4 Introduction ................................................................................................................................................... 6 Process Considerations ................................................................................................................................. 7 Feedstock .................................................................................................................................................. 7 Receiving/Pre-processing .......................................................................................................................... 7 COCCUS Digestion ................................................................................................................................... 7 Technology Overview ........................................................................................................................... 8 Post Processing ........................................................................................................................................ 9 Biogas Utilization ..................................................................................................................................... 10 Pricing Estimate .......................................................................................................................................... 10 Summary ..................................................................................................................................................... 10 Process Flow Diagram ................................................................................................................................ 11 Page | 4 BIOFermTM Energy Systems www.BIOFermEnergy.com info@BIOFermEnergy.com COMPANY PROFILE BIOFerm™ Energy Systems BIOFermTM Energy Systems is a Madison, Wisconsin based company providing anaerobic digestion technology for renewable energy generation and waste management to North American operations. Committed to sustainable and economical organic waste diversion, the BIOFermTM technology utilizes anaerobic digestion to harness biogas rising from fermenting organics—food waste, manure, biosolids, etc.—converting it into valuable green energy, heat, fuel, and more. As a member of the multi-billion dollar family company, the Viess mann Group, BIOFermTM has industry experience from over 400 global digester installations. Our company offers the industry’s best performance guarantee for our digester technology, and has a high occurence of repeat business. We also provide a complete range of digester systems to clients: from low to high solids, from small -scale to industrial-sized, and for applications as diverse as campuses to dairies to municipalities and much more. These systems provide a valuable set of advantages for the client, in cluding carbon neutral energy production, system reliability, waste volume reduction, system simplicity, fully automated management control systems and energy expenditure savings. Page | 5 BIOFermTM Energy Systems www.BIOFermEnergy.com info@BIOFermEnergy.com Biogas produced can be combusted in a combined heat and power unit (CHP) to make renewable heat and electricity. Alternatively, biogas can be upgraded to renewable natural gas (RNG) quality for use as vehicle fuel in the form of compressed natural gas (CNG), or injection into the natural gas pipeline. Biogas production, upgrading, and gas-to-grid injection facilities to be supplied from a single source through the Viessmann Group’s comprehensive product range. As a member of the Viessmann Group, BIOFerm TM provides biogas upgrading technology in North America via Carbotech —one of the world’s leading suppliers of biogas pipeline injection systems and gas upgrading technology. Carbotech has been a recognized pioneer in the biogas industry for over 40 years in the development, engineering and manufacturing of biogas upgrading systems and other gas processing. Today, over 900 of Carbotech’s Pressure Swing Adsorption (PSA) systems have been installed, including CNG and natural gas pipeline injection projects. Furthermore, Carbotech draws on extensive experience in gas purification and gas generation processes, such as the production of hydrogen and nitrogen. Carbotech biogas upgrading plants have been in operation in numerous countries with reliable, highly efficient and low operational costs for the processing of biogas to renewable natural gas. Page | 6 BIOFermTM Energy Systems www.BIOFermEnergy.com info@BIOFermEnergy.com INTRODUCTION The City of Hoonah, Alaska, is a village of about 800-900 people near Juneau, Alaska. Hoonah is on an island with no road access and it only accessible via a 20-minutes flight by small airplane or a 2-hour ferry ride fro m Juneau. The cost of electricity is $0.64 per kWh from diesel generators. With this high expense, Hoonah is looking to reduce their reliance on diesel electricity generation. The city of Hoonah has access to waste activated sludge, which is a collection of the biomass particles produced during the growth of organisms during wastewater treatment in aeration tanks. A preliminary investigation into the potential use of anaerobic digestion as a disposal method of this material has been investigated by BIOFerm™ Energy Systems. With the amount of waste activated sludge that was deemed collectible from Auke Bay, Mendenhall and Juneau-Douglas wastewater treatment plants, an estimate of biogas production and electrical output via combined heat and power (CHP) has b een attached for your reference. This high level estimate assumes rough characteristics of the waste activated sludge and BIOFerm™ proposed two different preliminary options for anaerobically digesting the material. Option 1 was to use two containerized, mixed-plug flow EUCOlino digesters. Option 2 was to use one COCCUS complete mix tank reactor. The drawback of using Option 1 was the size constraint will not allow processing of additional waste streams (i.e. food waste) without displacing some of the wa ste activated sludge material. The drawback of using Option 2 is the conveyance and mixing setup of the tank system may require additional liquid for pumping and mixer agitation; however, the tank reactor could be sized large enough to accept additional streams of organic waste and ultimately produce more biogas. After initial conversation with Janette Keiser of J. Keiser & Associates LLC, Option 2 was selected for further detailed feasibility analysis as outlined in this report. This report replaces the previous feasibility report dated December 15, 2014. Page | 7 BIOFermTM Energy Systems www.BIOFermEnergy.com info@BIOFermEnergy.com PROCESS CONSIDERATIONS Feedstock The primary feedstock for the City of Hoonah is identified as waste activated sludge (WAS) from the City and Borough of Juneau, which owns and operates three wastewater treatment plants. The Auke Bay wastewater treatment (ABWTP) plant trucks it’s WAS to Mendenhall wastewater treatment plant (MWTP) for combined dewatering. The third plant, Juneau Douglas wastewater treatment (JDWTP) plant is independent of the other two. The total estimated tons produced are as follows with the assumption of ~15% total solids content: Location Amount (wet tons/day) Amount (dry tons/day) ABWTP + MWTP 14.6 2.19 JDWTP 3.9 0.59 TOTAL 18.5 2.78 Receiving/Pre-processing Biosolids would be delivered to the City of Hoonah from Juneau via barge transportation. Further analysis as to the schedule and volume of barge deliveries needs to be evaluated. Additionally, due to the nature of the feedstock (i.e. total solids content estimate near 15%), the handling of the waste stream may be directly pumpable or require additional dilution liquid (feedstock). With this in mind, the process flow diagram attached indicates two possible feeding options for the anaerobic digestion system and the COCCUS® tank setup. Feeding Option 1 relies on the assumption that the biosolids material is too thick for conventional pumping into the complete-mix COCCUS® tank and therefore it is combined with an additional substrate for dilution (undefined at this time) in a Quick-mix solid/liquid pumpTM. This feeding option also allows for additional substrate incorporation and therefore additional potential energy generation. Feeding Option 2 relies on the assumption that the raw delivered biosolids are pumpable and do not requi re dilution prior to entry into the COCCUS® tank reactor. The sizing of substrate storage is large enough to hold the barge delivery amount so consistent feeding can take place. COCCUS Digestion This feasibility analysis focuses on the use of the COCCUS® complete-mix tank reactor for anaerobically digesting the biosolids feedstocks. The minimum sizing of the COCCUS ® is 500 m3 of storage volume, but could be built larger for additional feedstock volume. Page | 8 BIOFermTM Energy Systems www.BIOFermEnergy.com info@BIOFermEnergy.com Technology Overview The COCCUS® digester tank was developed for efficient biogas production from food wastes, liquid manure, biosolids, agricultural waste, energy crops, and other low solids organics. The COCCUS® is a complete-mix anaerobic digester operated in the mesophilic temperature range. BIOFerm™ Energy Systems utilizes the Schmack COCCUS® tank reactor for input materials with low solids content, including percolate liquid from high solids anaerobic digestion. Retention time in the reactor varies by type of substrate and is established to maximize efficiency in methane production over time. The digester design incorporates an effluent recycle line to assist in system buffering and improved biogas output. View of complete-mix COCCUS anaerobic digester 1) PASCO Feeder 2) CALIX 3) EUCO plug-flow digester 4) COCCUS CSTR 5) CHP 6) Transformer 7) SULA final storage Page | 9 BIOFermTM Energy Systems www.BIOFermEnergy.com info@BIOFermEnergy.com The complete-mix COCCUS® digester is equipped with large REMEX paddle mixers and incorporates a gas storage region located above the liquids in the vessel. The digester achieves optimum fermentation through the deep, slow and continuous agitation of the REMEX® Paddle Mixer inside the tanks. This low power consuming mixer ensures homogenous horizontal and vertical mixing, low maintenance requirements, low failure rates, robustness and durability, and the eliminati on of sinking and swimming layers. The process results in well mixed effluent for post-digestion nutrient recovery systems. In addition to the optimized plant control and two independent heating loops, the large paddle mixers inside the COCCUS® digester contribute to its high efficiency. The mixers are controlled via variable frequency drives, which enable modulation of the power consumption of the mixers in response to the input material to save mixing energy. The drive motor of the mixer is mounted onto t he outside wall of the COCCUS® so that only the long-life, self-lubricating polyamide bearings are located inside the fermenter. Internal view of COCCUS® featuring REMIX® mixers and wooden roof structure for desulfurization Post Processing Post anaerobic digestion, the effluent will have a reduced total solids content compared to the input materials. The process flow diagram estimates the total volume and solids content of the biosolids without any additional feedstock. The post processing effluent can incorporate the optional separation step which will fractionate the liquid and solids portions of the effluent stream. Various technologies exist with different degrees of solids capture rates which are to the client’s discretion. Solid and liquid fractio ns can be used for fertilizer or can be processed further to make compost. The use of biosolids as the feedstock input may require post pasteurization if the solids or liquids are to be used on crops for human consumption. Page | 10 BIOFermTM Energy Systems www.BIOFermEnergy.com info@BIOFermEnergy.com Biogas Utilization The identified biogas use for the City of Hoonah is electricity generation to offset the reliance on diesel. The production of electricity and heat can be completed through the use of a combined heat and power unit (CHP). The process flow diagram depicts the sizing and estimated output for the facility processing only biosolids as a waste stream. The resulting output is approximately 745,000 kWh per year of electrical energy. Additionally, excess heat generated by the unit could be used for external sources. PRICING ESTIMATE For this preliminary feasibility, BIOFerm™ can only provide a generic budgetary model for a single tank wet digestion plant. For more detailed budgetary models of specific plant designs, BIOFerm™ will need to establish a design contract. Component Costs ($) Equipment and Materials 1-COCCUS® 500 Complete Stirred Tank Rector $278,581 1-100 kW MAN® “filius” CHP Engine $202,374 Biogas Treatment Skid $88,872 Installation and Support Services (CHP) $12,000 Initial Supply of Glycol and Oil $3,200 Shipping to Hoonah, AK $40,000 TOTAL Equipment + Materials (with CHP shipping) $625,027 Construction $231,000 Engineering, biological services, construction management, commissioning. $383,000 Contingency $117,000 TOTAL FACILITY PRICE* ($) $1,356,027 *Not Included: Permitting and Interconnection. SUMMARY Based on the Monthly Generation for IPEC’s Hoonah Power Plant, the average kWh usage over the past three years is approximately 4,776,603 kWh which is roughly 545 kW of continuous use. The anaerobic digestion of Waste Activated Sludge from the Juneau area would account for 15 – 20% of this load without additional feedstock. Additional feedstocks, laboratory analysis, delivery methods, post digestate use, and site characteristics are just a few topics that need to be addressed in order to help define and estimate the energy potential and cost of this project. Page | 11 BIOFermTM Energy Systems www.BIOFermEnergy.com info@BIOFermEnergy.com PROCESS FLOW DIAGRAM Please find the process flow diagram below: