PROPOSAL

FOR A BIOGAS PLANT FOR A 45 TONNES/HOUR FFB PALM OIL MILL

This document is the property of GLOBAL WATER ENGINEERING (GWE) Ltd., Hong Kong. It shall not be copied, reproduced, transmitted or communicated to third parties without the explicit agreement of GWE. International Conventions of Berne (1886) - Paris (1896) Berlin (1908) Berne (1914) Rome (1928) Brussels (1948).

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TABLE OF CONTENTS
1. 2. COMPOSITION OF THE WASTEWATER .................................................................................................................. 1 PROCESS DESCRIPTION.............................................................................................................................................. 2 2.1 3. ANAEROBIC WASTEWATER TREATMENT (PROCESS FLOW DIAGRAM D101P-A + D101P-B) .............................................. 2

BASIC DESIGN DATA.................................................................................................................................................... 6 3.1 3.2 3.3 3.4 3.5 3.6 EQUALIZATION/COOLING OF THE WASTEWATER .............................................................................................................. 6 MIXING TANK (B105) ..................................................................................................................................................... 6 METHANE FERMENTATION (D101) .................................................................................................................................. 6 DBF TANK (S103) + SATURATOR (I102) + SLUDGE COLLECTION TANK (B106) .................................................................. 7 CONSUMPTION OF CHEMICALS ........................................................................................................................................ 7 BIOGAS REUSE ........................................................................................................................................................... 8

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SHORT TECHNICAL DESCRIPTION .......................................................................................................................... 9 4.1 MECHANICAL EQUIPMENT .............................................................................................................................................. 9 4.1.1 Anaerobic treatment (Process Flow Diagram D101P-A + D101P-B)..................................................................... 9 4.2 PIPING .......................................................................................................................................................................... 16 4.3 INSTRUMENTATION-AUTOMATION-ELECTRICAL ............................................................................................................. 16 4.3.1 Wastewater treatment (Process Flow Diagram D101P-A + D101P-B)................................................................ 16

5.

DRAWINGS ................................................................................................................................................................... 19

PROPOSAL
CLIENT:

PROJECT:

BIOGAS PLANT

PROJECT No: BY :

SHT 1

1. COMPOSITION OF THE WASTEWATER ================================= The design waste production quantity, as well as all influent composition values are based on the specifications from the client and on our past experience with a large number of palm oil mills. From these data following design figures are obtained: Factory capacity : Specific wastewater production : Design flow rate : COD COD COD BOD5 BOD5/COD ratio TS TSS pH Temp. : : : : : : : : : 750 Tons FFB/day = 45 Tons FFB/h, 16.7 h/day 80 % of FFB m3/d 800 3 m /h 25.0 (24 h/d, after equalization) mg/l 55,000 kg/d 33,000 kg/ton FFB 44.0 mg/l 27,500 0.50 mg/l 43,600 mg/l 19,000 --45 C 70 80

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BIOGAS PLANT

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SHT 2

2.

PROCESS DESCRIPTION ===================== 2.1 Anaerobic Wastewater Treatment (Process Flow Diagram D101P-A + D101P-B) The POME from the factory flows by gravity into an equalization pond (B101, out of GWE scope). From the pond the POME is pumped (by means of P111A/B) into a mixing tank (B105) where the pH adjustment is done with caustic soda (F101, P103). This pH adjustment is particularly important in the initial start-up period (first 2-3 months). After that, the caustic soda requirement will drop and may even become zero (stand-by only).

The mixing tank is covered and mixed with a top entry mixer (A105). The influent is pumped (P101A/B) from the mixing tank into the digester (methane reactor D101).

Under certain circumstances (start-up, restart after outage, ) it might be necessary to heat the wastewater in order to obtain and keep thermophilic conditions in the methane reactor. For this purpose we have included a hot water boiler (H102). Hot water produced in the boiler H102 is pumped (P113) over a spiral heat exchanger (E101) to heat the wastewater to the desired temperature (about 55C). The boiler operates normally on LPG or propane but it is also possible to use biogas. The biogas can be fed to the hot water boiler H102 by means of a biogas blower (C101), preceded by a demister (S102). REV DATE DESCRIPTION BY CHK -

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BIOGAS PLANT

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SHT 3

For this type of wastewater, sludge with poor flocculating and settling characteristics (no granulated sludge), is expected. This is mainly caused by the high TSS, high COD, high protein and high inorganic salt content of the wastewater. For this reason, GWE selected the FLOTAMET-M process which consists of a methane reactor (D101) followed by a sludge flotation stage (S103).

In the methane reactor the actual anaerobic fermentation takes place. Dissolved and suspended organic matter are largely degraded by anaerobic bacteria (sludge), and converted into biogas, a mixture of methane and carbon dioxide. Only little sludge growth takes place during this process. The methane reactor is of the ANAMIX-T or CSTR type. In the methane reactor (D101), the wastewater enters at the bottom and rises through an expanded bed of anaerobic active methanogenic sludge. Good mixing by means of a top entry agitator (A103) ensures that the influent is in constant contact with the biomass.

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BIOGAS PLANT

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SHT 4

The effluent of the methane reactor flows to a special Dissolved Biogas Flotation cell, called DBF-tank (S103). In this DBF tank, the anaerobic sludge flocs escaping the anaerobic reactors are separated from the treated wastewater by flotation and recycled. The principle of the Dissolved Biogas Flotation is similar to the Dissolved Air Flotation, but using biogas instead of air. In the DBF-tank, the solids are forced to float by fine biogas bubbles attaching to the solids. The fine biogas bubbles are created by recycling clean effluent (P123A/B), in which biogas is dissolved under pressure. This happens in the saturator (I102) where biogas is dissolved under pressure (about 5 bar) by means of the biogas compressors C104A/B. After injection of the recycle flow in the DBF tanks, the sudden pressure release results in the formation of fine biogas bubbles, which float to the surface, dragging the sludge flocs with them. The separated foamy sludge flows out of the DBF tank through a conical section at the top, and is collected in a sludge tank (B106), from where it is returned (P106A/B) to the mixing tank. Addition of a flocculation agent (polyelectrolyte) is foreseen (M101 + P122A/B) in a pipe flocculator (A107) in front of the DBF-tanks, to increase the flotation efficiency and improve the effluent quality as needed. Excess sludge can also be withdrawn from this sludge tank B106. The clarified outlet of the DBF tank is discharged or sent to the existing lagoons (out of GWE scope).

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BIOGAS PLANT

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SHT 5

For safety and start-up reasons a flare (H101) is foreseen.

Elevated flare

Groundflare

In basis, an elevated type of flare (H101) is foreseen. This type of flare is the cheapest type of flare, but is not CDM compliant. However, since the biogas is used for electricity generation, under normal circumstances no excess biogas is to be flared off. The flare is mainly needed for start-up and emergency use. In option, an additional price is given for a temperature controlled ground flare, which is 100 % CDM compliant.

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BIOGAS PLANT

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SHT 6

3.

BASIC DESIGN DATA =================== 3.1 Equalization/Cooling of the Wastewater 3.2 This is done in an equalization basin (B101, out of GWE scope) wastewater flow : 600 m/d, design value required hydraulic retention time for equalization and cooling: 1 day minimum 3 corresponding active basin value: 600 m minimum influent temperature: 80C max. temperature after equalization: 55 - 65C

Mixing tank (B105) incoming flow from the equalization pond: 600 m/d = 25 m/h recycle flow from anaerobic treatment : 100 % or 25 m/h (of which part from the sludge tank B106 and the rest from the methane reactor D101). total incoming flow: 50 m/h required residence time: 1 h corresponding volume: 50 m

3.3

Methane Fermentation (D101) wastewater flow : 600 m/d. design value, or 33.3 m/h, design value (after equalization), 24 h/day COD influent: 55,000 mg/l; 33,000 kg/d BOD5 influent: 27,500 mg/l; 16,500 kg/d design hydraulic retention time: 10 days corresponding methane reactor (D101) water volume: 6,000 m3 corresponding volumetric loading rate: 5.5 kg COD/m.d number of reactors: 1 dimensions of the reactor: . liquid height: 11.5 m . total cylindrical height: 12.0 m . cross section : 522 m, diameter: 25.8 m minimum COD total effluent: 8,250 mg/l BOD5 total effluent: 2,200 2,750 mg/l TSS effluent: 3,000 mg/1 COD total reduction: 85 % BOD5 total reduction: 90 - 92 % Biogas production: 16,362 Nm biogas/d or 9,817 Nm CH4/d at 60 % CH4

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BIOGAS PLANT

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SHT 7

3.4

DBF tank (S103) + saturator (I102) + sludge collection tank (B106) Wastewater flow rate from factory: 25 m/h max Sludge recycle from sludge tank (B106) to the anaerobic treatment: 50 %, which is 12.5 m/h Net flow rate to the DBF tanks: 25 + 12.5 = 37.5 m/h Max acceptable surface loading rate for the DBF tank: 6.0 m/m.h Required flotation surface: 6.25 m minimum 1 DBF tank of 3.2 m diameter Corresponding available flotation surface: 8.04 m HRT in sludge collection tank (B106): 20 minutes Corresponding volume of B106: 4.2 m Saturation recycle: 100 % of total incoming flow, 37.5 m/h HRT in saturator (I102): 3 minutes Corresponding volume of I102: 1.9 m minimum TSS load to saturator: 37.5 m/h x 15 kg TSS/m = 563 kg TSS/h Required biogas/TSS ratio: 0.05 kg biogas/kg TSS Corresponding required biogas: 28 kg/h or 23 Nm/h (density biogas at 60 % CH4 is 1.214 kg/Nm)

3.5

Consumption of Chemicals Caustic soda (NaOH) Especially during start-up, some caustic soda will be necessary to control the pH of the methane reactor. After start-up, this caustic soda dosage will eventually decrease, and will most probably become zero (stand-by only). the maximum required amount of caustic soda is around 27.5 meq/l, or 1.1 kg pure NaOH/m raw wastewater corresponding maximum caustic soda dosage: 600 m/day x 1.1 = 660 kg/day, or 1,320 kg/day of a 50 % NaOH solution at a density of 1.54, this means 857 l/day (36 /l/h)

NaOH will only be needed at start-up, and in exceptional circumstances (calamities, upsets, overload, ) The projected NaOH consumption in normal operation is expected to be zero, based on the following arguments: High TKN-content of the wastewater, which results in a high buffering capacity of the wastewater. REV DATE DESCRIPTION BY CHK -

PROPOSAL
CLIENT:

PROJECT:

BIOGAS PLANT

PROJECT No: BY :

SHT 8

Thermophilic operation of the methane reactor (more CO 2 is stripped from the wastewater to the biogas than in mesophilic operation). Our process design including a large effluent recycle + a mixing tank (B105). Both measures contribute to a reduction of the NaOH consumption. 3.6 Biogas reuse 1 Nm /day biogas at 60 % CH4 has a calorific value of 5,142 kcal, so total expected biogas production is equivalent with 3,505,000 kcal/h (thermic). This is equivalent with 4,076 kW (thermic) or 1,549 kWe (at 38 % net conversion efficiency). Part of the biogas can be reused to heat the wastewater if required. Maximum required heat capacity: 25 m/h x (55-35)C x 1,000 kcal/m.C = 500,000 kcal/h Corresponding amount of biogas required: 97 Nm/h, or 14 % of the available biogas. If no biogas is available, LPG or propane is to be used. Note that these are calculated values based on the design COD input and expected removal efficiency figures. Actual figures will vary with the quantity and composition of the factory effluent
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BIOGAS PLANT

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SHT 9

4.

SHORT TECHNICAL DESCRIPTION =============================== 4.1 Mechanical Equipment 4.1.1 A103 Anaerobic treatment (Process Flow Diagram D101P-A + D101P-B) : slow running vertical agitator, 22 kW, all wetted parts in stainless steel

A105

mixing tank agitator, top entry mixer in stainless steel, 2.2 kW, with mounting/lifting accessories

A107

In line pipe flocculator, capacity 40 m/h.

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BIOGAS PLANT

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SHT 10

B101

equalization basin, 600 m net volume minimum (OUT OF GWE SCOPE) mixing tank, concrete, 50.6 m volume, internal length x width = 4.5 m x 4.5 m, water height : 2.5 m, total height : 3.0 m

B105

B106

Sludge tank, closed with conical roof, 40 mbar pressure, 4.2 m net volume, approx. dimensions: diameter 1.5 m, cylindrical height 2.8 m, active height 2.4 m Biogas blower, capacity 100 Nm/h at 150 mbar, centrifugal type, wetted parts in cast aluminum and stainless steel, 3 kW.

C101

C104A/B

Biogas compressors (1 stand by), 25 Nm/h at 5 bar, 5 kW

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BIOGAS PLANT

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SHT 11

D101

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methane reactor (ANAMIX-T) vertical cylindrical concrete tank with a conical or dome roof (design under roof pressure: 500 mm W.G.) diameter: 25.8 m; cylindrical height: 12.0 m internal piping in HDPE coating : (coaltar) epoxy coating inside in the gas phase

E101

spiral heat exchanger, in AISI 316, 500,000 kcal/h, capacity, to heat the influent

F101

caustic soda storage tank, carbon steel or HDPE, content 30 m

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BIOGAS PLANT

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SHT 12

H101:

BASIS Biogas safety flare, 900 Nm3/h capacity, elevated type, in stainless steel, fully automatic operation

H101:

OPTIONAL Biogas flare, 900 Nm/h capacity, temperature controlled, groundflare, in stainless steel, fully automatic operation

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BIOGAS PLANT

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SHT 13

H102

Hot water boiler, biogas fired water heater, convertible to natural gas (start-up period), capacity 581 kW (500,000 kcal/h), safety control: control panel, safety valve, temperature switches and temperature transmitters, O2 trim control, VSD on combustion air blower

I102

Saturator for the DBF tanks, capacity: 37.5 m/h, active volume: 1.9 m, stainless steel, operating pressure: 5 bar

M101

Automatic polymer operation unit, capacity 1.7 kg PE/h, material SS AISI 304, accessories 3 mixers = one in each of the 3 compartments, 1 powder screw feeder with hopper

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BIOGAS PLANT

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SHT 14

P101 A/B

methane reactor feed pumps (1 stand by), horizontal centrifugal pumps, 50 m/h at 20 m W.C., 5.5 kW caustic soda metering pump (1 stand by), 0 - 160 l/h automatically adjustable (frequency control), 0.55 kW

P103 A/B

P106 A/B

Anaerobic sludge pumps (1 stand by), positive displacement mono pump, 15 m/h, automatically adjustable (frequency control), 3 kW. influent pumps, excenter screw pumps (mono), 30 m/h, 5.5 kW automatically adjustable by variable speed drive.

P111A/B

P113

Hot water recycle pump, 50 m/h at 12 mWC, 4 kW, horizontal centrifugal pump Polymer dosing pumps (1 stand by), mono pump with integrated frequency converter, capacity 2 m/h, 0.75 kW Saturation recycle pumps (1 stand by), 40 m/h at 5 bar, 11 kW

P122A/B

P123A/B

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BIOGAS PLANT

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SHT 15

S102

Biogas demister, for 100 Nm/h biogas, cylindrical tank in stainless steel with built-in demister pad.

S103

DBF-tank (Dissolved Biogas Flotation cell) package unit. Compact sludge separator with conical roof, sludge outlet section, inlet diffuser, concave bottom with 4 clarified effluent outlet points, 4 sample points, access ladder. Cylindrical coated carbon steel tank, with legs. Overall dimensions: - total height = 8.0 m - internal diameter = 3.2 m

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BIOGAS PLANT

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SHT 16

4.2 Piping wastewater HDPE + stainless steel AISI 304 around equipment biogas stainless steel AISI 304 chemicals carbon steel or HDPE process water carbon steel or HDPE Piping supports in painted or galvanized carbon steel Valve materials in accordance with piping materials 4.3 Instrumentation-Automation-Electrical Complete set of instruments for safety and largely automatic operation Preliminary list (can be changed during detailed engineering) Instruments included in packaged units (flare, dosing pumps, BIO-SULFURIX) not included. 4.3.1 Level Wastewater treatment (Process Flow Diagram D101P-A + D101P-B) 1 level probe/transmitter ultrasone type (LE/LT108) 2 level probe/transmitters hydrostatic type (LT105, LT106) 2 level control valves (LCV105, LCV109) 1 level probe/transmitter (differential pressure) (LE/LT110) F F F F

Flow

6 electro-magnetic flow meters (FE/FT100, FE/FT101, FE/FT102, FE/FT109, FE/FT110, FE/FT111) F 3 flow control valves (FCV101, FCV102, FCV110) F 2 biogas flow meters (mass flow type) (FE/FT103, FE/FT105) F 2 pressure transmitters (PT102, PT103) 8 pressure gauges 1 pressure control valve (PCV102) 2 temperature probes/transmitters (TE/TT101, TE/TT102) 1 temperature control valve (TCV101) 2 pH probes + electrodes + cables (pHI101, pHI102) 2 pH transmitters (pHT101, pHE102) 1 online CH4 meter (AT101) 8 frequency controllers (SC100, SC103, SC106A/B, SC111A/B, SC122A/B) DESCRIPTION BY F F F F F F F F

Pressure

Temperature

Analysis

Control

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BIOGAS PLANT

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SHT 17 F F

Safety & Miscellaneous

1 breather valve (SB101) 1 flame arrestor (SF101)

Breather valve/Flame arrestor

Low tension/control panel Central low tension/control panel. All equipment is operated from the SCADA computer (see below). However, the panel is equipped with AOM switches allowing manual operation of the motors for maintenance or in case the PLC/Scada system is down.

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BIOGAS PLANT

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SHT 18

PLC/Scada System Specification The Plant has a PLC, brand Allen Bradley model COMPACT LOGIX. All logic and timing is done by this PLC.

All indications and alarms, as well as reporting on the daily operation of the plant, and trending will be done by a Scada computer system. All motor start/st op as well as auto/manual functions are also done from the Scada computer. The SCADA software used is SPECVIEW. A simplified flow sheet will be displayed on the Scada computers colour screen, featuring all measurements (continuously updated) and indication of operating motors. Alarms will be indicated by a colour change to red of the corresponding measurement or indication. An external acoustic alarm is also foreseen.

The measurement values are stored on the PC's hard disk, and are used as computation values for a daily plant operation report, printed by the PC's printer. There is a possibility to introduce external (off-line) data from laboratory analysis (COD, ) in order to make the plant operation report complete. In absence of such external data input, the computer will use the design values as default values. REV DATE DESCRIPTION BY CHK -

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BIOGAS PLANT

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SHT 19

5.

DRAWINGS ========== Attached following drawings: Flow diagram: Giving all equipment, main process lines and all instrumentation except pressure gauges (PI) and temperature gauges (TI). D101(A+B): Anaerobic treatment

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