Optimization of integrated Clean production of Pyro gas, Biogas Methanol,

Bioelectricty, Fertilizer and Feed from agro wastes with Reduced Emission.
Pannirselvam P.V*1, Mario Cardoso³, Alexandre H. F. Costa, Maricy .M.Cansian and Rajesh S.
Kempegowda 2
a
Departamento de Engenharia Química /CT. Universidade Federal do Rio Grande do Norte, Natal-RN.
59078400. Brazil.
*1
Coresponding author: pannirbr@gmail.com, www.ecosyseng.wetpaint.com
2
Dept of Energy & Process Engineering, NTNU, Trondheim, Norway
3
Dept

Abstract

Brazil is the leader known for its ethanol biofuel development, but also for biomass charcoal, yet lacks in
clean rural biofuel and bioenergy production.This paper deals with the system design based on zero
emission for sustainable projects developments based on the the bioenergy production from biomass
wastes using innovative process equipments design and the process optimization The main objective is
towards development of sustainable small scale not only clean energy production as well as with co-
production of hot and cold thermal energies from bio wastesAgro industrial waste pose a major concern
today, as with the increase of production with time ,which need ecological solution. For this problem, an
integrated dream energy farm with the Small Bio-Systems (SBS) based on the Zero waste concept was
studied by the three basic principles. The first principle is to use all component of the biological organic
materials of the wastes. The second principle is to obtain at least two products from the waste. The third
principle is to close the loop via reuse, recycle and renewal of the material and nutrient flows. The SBS
approach has many benefits and potentials The system design was for small-scale energy production
using hybrid bio-fuel and internal combustion engine from wastes was made using process analysis
(synthesis, modeling, and design) of two stage anaerobic bio process.SuperProProcess simulation
software was used to evaluate these options and performs mass material balances.A case study was
made with the anaerobic process in several stages and recycle of reactor out put are found to be very
use fuel to increases the biomass load and also the productivity when used with baffled and up flow
reactor to produce, biofertilizer, bio-hydrogen, bio-methane ,charcoal, biofertilizer , methanol and Electrical
energy with recycle of water and microbial biomass, which are integrated to Internal Combustion engine.
Existing biogas technologies has potential for practical application, but if biohydrogen systems are to
become competitive, they need more detailed integrated two stage biohydrogen and methane bio reactor
to enhance the efficacy of biofuel utilization for energy needs.The results obtained from several
preliminary project developments with few case studies are reported for integrated project developments
for fuel and food using process and cost simulation models. These models render the process
development problem with economic potential objectives to be solved very rapidly and make it possible in
optimization of the integrated system and minimization of residues. Several economic problems related
with implementation of the small scale rural energy system for sustained local developments based on
tropical fruit production in rural areas are analysed and a concept of the integrated biosystem for micro
enterprise has been proposed will be implemented in the north east region of the Brazil.

Key Words: Waste, Energy, Biomass, Syngas, Biogas, Pyrolysis, Methanol

1.Introduction.
The two major challenges in global energy systems are to reduce energy related greenhouse gas
emissions and to maintain energy supply security. This thesis presents one solution to both problems. It
proposes strategies for the transformation of currentenergy systems into 100% renewable, stable and
almost emission free energy systems without making use of nuclear energy or carbon capture and
storage.Within renewable energy systems, one is facing two difficulties: On the one hand, the fluctuating
renewable sources need to be matched with the energy demand, on the other hand, a substitution for high
energy density fuels in heat and transport has to be found.
Therefore, this work examines bioenergy and the newly developed ‘renewable power biohydrogen
.methane and methanol’ or ‘renewable methane and methanol ’ concerning their potential to solve these
problems using clean technology developing concepts using moder computer suytems and process First,
bioenergy is analyzed in the broader context of climate change, energy systems and land use in order to
estimate the sustainable potential of global bioenergy and brazilian bioethanol concepts. Then, a techno
economic and ecologic analysis of several bioenergy pathways is done in order to identify the strategic
role of bioenergy in future energy systems. The potential is linked with this analysis to identify the range of
maximum greenhouse gas reduction potential of bioenergy . Second, to solve this bioenergy bottleneck, a
new approach of converting renewable power into biohydrogen and methane via hydrogen and CO2
synthesis is developed developed. Several integrated concepts with CO2 from air, biomass, and fossil
fuels are designed. In this way, renewable power can be stored in methanol patially flexible for balancing
power, for process heat and for long distance transportation. It can be produced basically anywhere where
water, air and renewable power are available and thus decrease import dependence on fossil fuels. It can
recycleCO2 in the energy system or even act as carbon sink in combination with CO2 storage.
Third, the necessary transformation of energy systems is performed. The key elements are direct
renewable power generation, renewable electromobility, renewable power methanol and overcoming
traditional biomass technology .. Several 100% renewable energy systems are developed, reducing
global energy related emissions by 95%. The 100% renewable power supply was simulated using proces
simualtion sotware .
Main research questions on clean bioenergy and climate change
One cannot neglect the fact that fossil fuels are depleting and the major cause of anthropogenic global
warming. At the same time, nuclear fuels are depleting as well and contain risks and unsolved problems
like waste disposal, making their use unfavorable.
Further, doubling nuclear power use reduces global greenhouse gas (GHG) emissions only by 4%.
Carbon capture and storage (CCS) technology reduces GHG emissions only to a certain extent, it does
not reduce fossil fuel dependency, and long term CO2 storage facilities are not yet tested. Energy
efficiency and energy savings can reduce energy demand and energy#related GHG emissions drastically,
but in the long run, energy systems will have to be based on renewables. Therefore, future energy
systems will be dominated by renewable energy sources.
The fundamental difference between today’s and future energy systems is that the expected main energy
sources, namely wind and solar energy, are of a fluctuating, unsteady nature. So far, fossil and nuclear
energy supply has been able to meet the flexible energy demand, while fuels basically are stored energy,
available for flexible use. Therefore, one main research question is how to match future energy supply
with energy demand at high shares of fluctuating energy sources, i.e. how to balance and integrate wind
and solar energy. Especially the transport sector is challenged and shaped by a high dependency on
fossil fuels and high density energy carriers. The heat sector can use solar and geothermal energy for
residential heating and warm water supply, but in some cases the base load is missing and especially
process heat is still highly dependent on natural gas. Thus, another main research question is how to
replace fossil fuels in heat and transport. In the power sector, many options are discussed to integrate
fluctuating renewable energy sources, for example virtual power plants on the supply side, demand side
management on the energy customer side and different transmission and storage options in between. No
silver bullet has been found yet and all options face difficulties: Increasing power transmission capacities
encounters resistance from local residents, pumped hydro storage or compressed air storage sites are not
sufficient or too far away from main power generation sites. This list can be continued. Bioenergy is an
attractive solution to the renewable energy integration challenge. It is renewable, but is has fossil fuel
properties like high energy densities and is basically stored chemical energy. It is therefore suitable to
substitute fossil fuels in transport, heat and power sectors and particularly interesting for balancing power.
In contrast, bioenergy has experienced a vigorous international discussion on its effect on climate change
and sustainability. Bioenergy use has a vivid history. Since the beginning of humankind, it was the energy
source number one: easy to access, easy to use, geographically well#distributed. Until the first industrial
revolution some 200 years ago, it was the main energy carrier and accounted for 99% of primary energy
demand. During industrialization, biomass has been gradually substituted first by coal at the beginning of
The conversion of biomass into valuable products such as fuel methane gas , ethanol ,methanol and
protein feed have been considered to be important by research centre, the central and state government,
industries and financial agents (1-6). Brazil has nearly 126.806.000 tones of total biomass wastes
produced per year as it is one of the major producer of agricultural crop such as cashew
,coconut,cassava, soyabean , coffee and sugar cane.The use of this lignocellulosic biomass has the
potential to solve the present economic crisis such as third world debt, air pollution due to burning, trash
disposal, deforestation, animal feed shortage and migration from rural area.
However, the economic utilization of the biomass waste are handicaped by the technical problems due to
the pre-treatments and slow bioconversion process (1-4) involved in biofuel production as well as
environmental problem. Economic and ecological utilization of the biomass wastes from tropical fruits such
as coconut, banana, cashew nut and cashew fruit processing is still problems as their energy valorization
involve very complex system design and operation [1-2]. Brazil is the leader known for its ethanol biofuel
development, and also for the biomass charcoal, but yet lacks much regarding the rural energy
production. There is a need to decrease the pollutants emitted by these wastes asvery huge quantities,
nearly 70% (seventh percent) of total generated, are considered to be wasted in Brazil and this makes
necessary to consider different alternative process, renewable energy source and co-product design from
these biomass residual.. This needs focus on system study of the clean biomass technology ,
cogeneration of energy and also the sustainable development approach for the small scale energy
production from wastes (1-5). The main objective of the present workalso is related to the current research
study made on the system design, analysis and optimization tools and methods which made possible to
the best value of the input variables and/or model parameters of the complex integrated biomass projects
for the total integral utilization agrowastes .The system design for small scale energy production from
wastes integrated with small enterprise related to agrowastes involve dynamic system models. This
system need to attain economic and ecological viability leading to the sustainable development of rural
villages with green energy.The novel flowsheet development for maxium ouput energy and minium wastes
is also our main objetive of the present work
Objective
The four main objectives of this thesis were (i) to identify the strategic role of sdelected biofuel and
bioenergy in future sustainable energy systems for Braziil and its potential in climate mitigation; and (ii) to
develop new concepts for storing and integrating renewable power generation via biohydrogen and
methanol (iii)to design integrated systems and stable 100% renewable energy systems with emission free
energy sources, and (iv), to make possible C02 emission reduction and analyze the importance and role
of the transformation towards 100% renewable energy systems in limiting global warming and climat
emission .V. Make possible tools to design clean bioenergy system relevant Brazilian biomass
feedstocks.

2. Selected Paths and Methods for generating energy from biomass wastes
In recent years, there has been seen considerable efforts devoted to the search for the best ways to use
the potentially valuable of biomass wastes sources for energy production by four diferent main methods, it
is possible to order them by the complexity of the processes involved[1-15]: 1 .Direct combustion of
biomass; 2. Thermo chemical processing to fuel;3. Biological conversion;4.Combined Anaerobic digestion
with pyrolysis. The main product, of some of these processes is heat, which is presently studied for the
use for the small scale fruit processing and milk dairy industry to generate heat via metane production
besides the need of the generation of "cold" effect, is also necessary, the production of hot water (around
50 ºC to 60 ºC) for cleaning of the facilities and processing equipments.(1) as well as the the
referigeration.
2.Pyrolysis: The thermo conversion for biofuel (syngas ) and energy production.
Pyrolysis is the simplest and almost certainly the oldest method of processing one fuel in order to produce
a better one. Conventional pyrolysis involves heating the original material (which is often pulverised or
shredded then fed into a reactor vessel) in the near-absence of air, typically at 300 - 500 °C, until the
volatile matter has been driven off. The residue is then the char - more commonly known as charcoal - a
fuel which has about twice the energy density of the original and burns at a much higher temperatures
made in almost all rural areas to make charcoal Fast pyrolysis of plant material, such as wood, baggasse
or nutshells, at temperatures of 800-900 degrees Celsius are under intensively study with pilot plant scale
using sugar cane bagasse.

Pyrolysis Reactor Conventional Present

Charcoal yield,% 30 25

Bio oil yield,% 0 35

Wood gas yield 70 40

Table 01: Slow Pyrolysis reactor designed to maximize the energy recoverycompared to
conventional charcoal making system.
Sugar Cane Bagasse and Napier Elephant grass anstudied in brasil for the pyrolysis had as little as 10%
of the material as solid char and converts some 60% into a gas rich in hydrogen and carbon monoxide.
This makes the fast pyrolysis a competitor with conventional gasification methods but like the latter, it has
yet to be developed as a treatment for biomass on a commercial scale.
The slow pyrolysis : We are able to make better reactor for small scale charcoal production with
characteristic properties listed in Table1 using conventional slow pyrolysis using ceramic kiln. Small scale
wood gasification project using simple brick wall construction was successfully demonstrated in several
remote rural are as, developed mainly in the decade of 80, now not employed much as it is not
competitive with the power generated with Internal Combustion diesel engines an the lack availability of
charcoal production as, developed mainly in the decade of 80, now not employed much as it is not
competitive with the power generated with Internal Combustion diesel engines an the lack availability of
charcoal production.
2.3 Anaerobic biodigestion: The bioconversion method for Bio fuel production (biohydrogen and
biogas ) The gas (Marsh Gas) obtained from the natural waste decomposition process, is a mixture of
Methane (CH4) and Carbon dioxide (CO2) .this gas is commonly called as the ‘Biogas’. Anaerobic
digestion, like pyrolysis, occurs in the absence of air; but in this case the decomposition is caused by
bacterial action. This is a valuable fuel which is in many countries produced in purpose built digesters
filled with the feedstock like dung and effluents from the dairy. The input is in batches, and digestion is
allowed to continue for a period of from ten days to a few weeks. A well-run digester using plug flow
bioreactor design operating at the farm in Brazil produce 200-400 m3 of biogas with a methane content of
50% to 75% for each dry tone of input. The biogas-production will normally be in the range of 0.3 - 0.45
m3 of biogas (60%methane) per kg of solid (total solid, TS) for a well functioning process with a typical
retention time of 20-30 days at 32°C. The lower heating value of this gas is about 6.6 kWh/m3. Often the
production is given per kg of volatile solid (VS), which for manure without straw is about 80% of total solids
(TS). Biogas applications from animal wastes or a large centralized manure processing system are
constrained by limited energy needs, storage complications, difficulties in exporting the energy, high
capital requirements, and complexities in operation and maintenance.. Many such systems use engine
waste heat in Europe, but mostly it is used for anaerobic digester heating .Biogas-fueled engine-driven
chillers are probably not suitable for most operations that are needed for fruit processing that would like
cooler temperatures than 42ºF to 44ºF for raw material and product storage ,as the cooler temperatures
are obtained by direct electric unit.In this work we study the slow pyrolysis for samll enegy generation.
2. INTEGRATED BIOSYSTEM DESIGN FOR CLEANER BIO ENERGY PRODUCTION FROM
AGRO BIOMASS.

Approach: Composting for bioferilizer and Anaerobic Digestion for biogas or both. Aiming at sustainable
development, the organic waste as a source of nutrients and energy has to be reused. Nowadays,
composting and anaerobic digestion (AD) are seen as the most favored options to deal with organic solid
waste.(Odum,2001; Hall,2002). Both treatment options reduce the environmental burden and enable the
generation of a nutrient rich fertilizer. Furthermore, in the case of AD, energy in form of biogas is
produced. Now a days, energy is scarce and their production out of biodegradable waste is willingly seen.
Thus, AD is attaining more relevance in SWM sector.In the past, this approach was rarely considered as a
feasible and sustainable solution for the SWM in developing countries.. But Information about the state-of-
the-art of these digesters as well as the study on the sytem for the minization of the water use is scarce.
(Chris, 2007)
BioEnergy from agrowaste : The gas (Marsh Gas) obtained from the natural waste decomposition
process is a mixture of Methane (CH4) and Carbon dioxide (CO2) and is commonly called as the ‘Biogas’.
Anaerobic digestion, like pyrolysis, occurs in the absence of air; but in this case the decomposition is
caused by bacterial action. This is a valuable fuel which is in many countries produced in purpose built
digesters filled with the feedstock like dung and effluents from the dairy, septic tank sewge sludge. (Kev,
2002; Nijaguna, 2002 Hall, 1992

Brazilina and Indian small system anearobic biogas technology:

In the recent past the planning, construction, operation or management of low-tech biogas plants has not
always been done appropriately, thus many projects failed (Pannirselvam, 1998;Chris,2007). The
selection of the following technologies is based on extensive research, means on literature review and e-
mail correspondence and has to be seen as scientific founded system analysis The following
technologies are primarily recommended for further evaluation and system sintheses of our work .

The technology of plug-flow (Figure 1a) reactor was designed specifically to handle organic waste for
production of biogas and manure by the Indian Institute of Science (IISc) Bangalore, South India..(Figure
1b). The system utilised green leaves, coffee pulp waste and the liquid effluent from manure. The gas
formed is utilised for cooking while the manure and liquid effluent are recycled in the fields. Within the first
year of demonstration, eight new systems are produced in large quantities in the world which
compounded by many different components such as paper, plastic, metal, glass, wood and other high-
moisture organic waste. Nygan, represented as green waste ( GW), food waste( FW), fruit and
vegetable waste(FVW) contributed by households, restaurants and markets.(Chris,2007)
BARC Biodigester, Mumbai: This kind of technology is said to be the state-of-the-art in the low-tech
context. Several plants work successfully in India and Sri Lanka, where water filtration using sand filter
and thermopilific hydrolysis are well demonstrated in a small scale system .(Chris,2007) Figure 1a
shows the details of this reactor.
ARTI Biodigester, Pune: It seems to be a promising technology. The small compact biogas plant is
applicable for households.

Figure 1 Solid waste Indian biodigestor

Brazilian project for small system for energy generation use biogas.
This technology is currently working based on the energy conservation strategy and efficient energy use.
In a confinement of 100 cows, a biodigester was designed to produce a volume of 118 m3 of biogas and a
generating group of from 8-15kVA and this to assist with electric energy the demand of the fruit processing
installation and water pump. The total demand of the biogas that working with these equipment is
estimated to be 85.3 m3 of biogas, which can be supplied with rest by the biodigester. This volume of the
biogas is enough one to generate mechanical energy using internal combustion engine adopted with the
gasoline Otto engine to run biogas and this to assist with electric energy to the demand of the fruit
processing installation and the pump for the chilling. The system design of cogeneration of energy and
heat is realized after the flow sheeting of several major components: Animal Production Facilities;
Manure/Effluent Handling System; Digester Tank (Figure 3 and 4); Heating & Mixing System Biogas
Cleaning & Handling System; Biogas Storage; Energy using biogas engine;. The heat pump selected for
this work is a novel system design based on the innovative and well optimized design. This is made
possible recently by the research group in UNICAMP/Brazil which can run using R22 heat transfer
refrigerant fluid. The use of ethanol and water mixture as heat transfer agent for heat pump to produce hot
water, chilling and ice making together with IC engine has been also well studied by this group. We apply
this UNICAMP/Brazil process to our integrated biowaste energy project. (Pannirselvam ,1998)

3. Materials and methods

Process Flow Sheet development: A conceptual design of the bioconversion process was constructed
using current laboratory and technical data. (10-15) The flow sheet development was done using
Superpro process simulator and other subsystems
( Material Balance and Process Yield: The general flexibility abstract simulation model was used for
material, energy balance and production costs calculation of conversion of particular substance and raw
material to final product via certain steps (n) and (n-1) intermediate substances. Theoretical conversion
factor, the efficient of the conversion, the processing cost of the conversion, the valorization of byproducts
and extra cost involved are the parameters used. From this, themaximumproduction cost was obtained
asfunction of process conversion efficiency and valorization make simulation with user input. These
process models were initially implemented with electronic spreadsheet and latter on SuperPRO 4.9,
Inteligen.Inc, and U.S.A. process simulator under window graphical operating system for microcomputer
(1) Process Economics Parameters and Costs Estimation: This project model and program had been
developed to evaluate rapidly the research and the preliminary biofuel project using limited number ofdata
that was obtained from laboratory research, allowing user to have estimates about the economics of
manufacturing in different scale of production.In our earlier work, we described the method of
development of this model (1). The input of process are:capacity (ton/year), yield, batch or continuos
process, high,average automation,maximum,temperature,andpressure,alloy factor of construction
equipment and the number of processing steps called functional units. More over the data on reactants
and products are: molecularweight, prices, stoichiometric ratio, product type as commodity, specialty or
intermediate product. Recently several process simulation software are widely ued for process flowsheet
development that can be applied to biomass utilization process, which also focus on the computer aids for
engineering process economics. Clean production of Bioenergy , Climate Change and climate Protection

4.RESULTS

The Bionversion system :This system is used for milk and fruit processing industry for the conservation
using the heat for pasteurization the cashew apple juice. The main equipments used are anaerobic
biodigester, the combustion furnace, the heat recovery system using heat exchangers are used for food
conservations.
The thermoconversion system:This case study made involves the slow pyrolysis system, making the
charcoal, the heat is recovered from exit flue gas, where as the second case study involved combined
pyroysis to make charcoal as well as gasification to produce gas , which was used for the internal
combustion heat engine for combined power and energy recovery.(4-9) for pyrolysis to make
charcoal(9,13)
The Cogeneration small energy system:The main assumptions made in the model are related to the
inferred value of the solids properties and the use of transfer coefficients for thermal and kinetics
constants. The values of these constants assumed are validated by the simulation results comparing it to
the real process published results. In the following Figure 1, the complex process scheme of the final case
study made based on the design for Environment using computer software. In this work, we designed the
flow sheet for the processing the waste and also the whole heat recovery system based on the biomass
fuel heating in regard to recirculation of the hot water. From the results obtained, it was observed that the
4.1 Optimum Configuration of integrated Bionergy Energy system design
Obviously there are many path ways and combination permutations that are available for the combined
use of the thermo conversion using pyrolysis and gasification or the bioconversion route. Before we
started the detailed case studies, we made with an energy audit of the animal and agro industrial wastes
feed stocks both in the production and processing units regarding energy demand and supply. After the
detailed study material balance of all the solid liquid flows using super pro simulation softwere tool which
has tools to make environmentla emission report , then we realized a tally of all of the energy uses
supplied using biomass. The energy and environmental audit is done using selected path ways nade few
case studies taking into account the energy consumed, the uncertainties of the biofuel supply based on
the scale and the efficiencies of biogas , biohydrogen , methanol syngas gas production. The entire
integrated system requirement of th e hyro pyrolysis , combined heat power (CHP)is first analyzed and
the process design was achieved from the result obtained by the process simulations and optimizations
and the result of several techno economical parameters.
Our result as well as the other studies show that significant amount of residues from cattle, goat, poultry
are required which are available plenty in rural areas as by the data obtained by our research work which
can be supplemented by the grater quantities of cashew apples and fruit waste and residues of the
production chain. The result is that export or energy generated from biomass wastes can be made
possible economically especially in the rural tropical areas in Brazil. The integrated system design
approach used in this made possible using cobined integrated bioconvesrion and thermoconversion
procoess determine whether the economics of selling electricity, fuel, the ice, the liquid fertilizer justifies
the higher incremental capital cost of the engine-generator, the associated higher maintenance costs, and
increased processing costs. The best optimized system has co-products together with the heat recovery
using heat pump coupled to the low cost gasoline engine adopted to the biogas. and bio hydrogen Thus
this making the system designed sustainable for rural people food processing and animal production chain
and environment too. Thus the system is made both economical and environmentally clean using several
simulation runs to optimize the system configurations after making the simulation of the process given in
the figure below. Our project is an integration of our two stge solid biodigetor technology and slow
pyrolysis process .This later one was adopted from the original conceptual design of BEST Energies Inc.,
which has been recently developed,, modified latter via NREL USA hyropyrolise for enhance hydroge
production This hydro pyrolysis technology consumes biomass waste streams while producing hydrogen
rich syngas and carbon-rich end products called biochar . The syngas is composed of combustible gases
including hydrogen, carbon monoxide, methane, and lower molecular weight hydrocarbons, as well as
nitrogen and carbon dioxide. This gas is cleaned by a series of unit operations before being recycled back
to the plant or exported. A portion of the gas generated is combusted and used as a heat source on the
pyrolysis kiln itself. An additional portion of the gas is combusted and used to dry the incoming feed
material for pyrolysis. The excess syngas gas represents the net energy output and can be utilized as a
fuel for an engine, an industrial boiler. The biohydrogen obtianed i s mixed with the hydrogen rich
syngas as a feedstock for down stream processes which refine the syngas into a liquid fuel methanol
using low temperature
The design involves operation of semi continuous small powerplant stand alone or integrated combined
heat, Cold and power applications .Our integrated Pyrolysis reactor and bidigestor holds a portfolio of
small scale rural village level technologies that significantly can improve the economics of pyrolysis and
thermo and bio gasification of biomass streams. These advancements are essential for the creation of
clean energy alternatives to traditional oil and biomass based combustion process which are actually
carried out . By bringing together the leading pyrolysis experts from around Brazil , Thailand and India via
international Congress Agrener, with more than 10 years of research and development experience in
design , we have created a rich, energy efficiency enhancements..Our Project solutions, all focused on
using on renewable bio-based resources, help the environment through proactively managing under-
utilized biomass streams, limiting CO2 greenhouse gases and providing effective carbon sequestration.
Our system provide an integrated, biogas and pyrogas scalable and distributed production solution which
has the ability to produce multiple clean energy streams.

System Optimization using computer modeling and simulation

Following are the tools and area where the intgerated biosystem are applied:
 1. System design work for decentralized energy production small scale rural, agro industrial are
under construction;
2. Several software tool for the system design, operating for rural sustainable fuel and food are
under development;
3. Implementation of nonconventional energy integration projects using Biomass as energy source
under study for Milk,cashew
The sustainable integrated Biosystem developed and projected consists of several sub system which are
outlined in the Figure 3 and 4. .The input and output of the system are shown clearly The details of the
design are illustrated in these figures are the biodigester, the effluent of the solid biogas system
feeding liquid waste , ABR reactor and biofilm reactor . They are projected to be running parallel and
result in organic liquid fertilizer for diverse uses. The main system components are in the Figure 4 and
the simulated system flow sheet is in Figure3,

Figure 4 Anaerobic baffeled bioreactor for fuel, feed and fertilizer

Also we made cash flow analysis for the closed and open use of the water system .The results obtained
of the project is the optimized design and also the economical parameters were analyzed . It is
observed that the economic return from fodder is more than fertilizer. Even though isolated biodigester
system is not economically viable as practiced ,but the integrated system has shown to be viable
economically , clean and environmentally sound so that a small farmer can produce energy competitive
with market price if the co products from organic fertilizer , feed fiber and fodder based on the small
scale

The detailed process economic analyses for the diverse case study are also important step towards the
solution to the complex problems of this project . The cogeneration system is too complex to be apply to
rural energy, require trained man power to design and operate but heat pump can be appropriate
technology for rural areas with lager energy savings. which will be outlined here .

Biohydrogen production:
Biological hydrogen production has been studied extensively since the 1970’s, but the technology has
progressed relatively slowly. Levin et al.42 classified the biological hydrogen production methods into the
following four groups:
Biohydrogen / Bio Reinary proposed flowsheet
The following flow sheet predicts the cashew processing and its waste effluent utilization for biohydrogen
production along with the conventional biogas. The flow sheet was proposed after studying various
patents. At the present time, dark fermentation and water-gas-shift are the only methods that have
feasible reactor dimensions for practical applications [Ginkel,2001]. Secondly, biohydrogen production by
dark fermentation is most interesting option for the conversion of organic wastes because of its analogies
to AD (anaerobic digestion).
Figure 5 Biohydrogen / Bio Refinary Projects
Two stage reactor comprising dark fermentation and water gas shift photo-bioreactors were considered
and shown in Figure 5. The size of the bioreactor for various process were give bleow in a Table 1.

Table 3 Comparative cost analysis of energy production

Two stage hydrogen Biogas fuelled Biofuelled IC

Levelised Cost
fuel cell (PEM) SOFC biogas-engine

Cost for biofuel production

0.087 0.08 0.08
US $/kWh

Cost for Gas cleaning 0.0016

0.0076 0.0076
US $/kWh

Cost for Fuel cell and its

0.119 0.129 0.045
Components :US US$/kWh

0.22
Total cost : US$/kWh 0.217 0.1591

Incase of biohydrogen, biohydrogen produced from the two stage bioreactor , the first hydrogen
production and then latter to methane production and then the gas obtained was sent after separating
CO2 and H2 obtained in the first reactor sent to the PEM fuel cells, purification was done only for PEM Fuel
cells where as in case of biogas utilization in SOFC CO 2 acts as a dilute one with direct use without co2
seperation (Figure¨6).The several basic principle of integrated biosystem with Zero emission were
applied to come with the flow sheet of figure 6.
CH4 acts as a fuel and converted in reforming section of external and internal reforming of SOFC. In fact
water is required in the reforming process of biogas to hydrogen. Although the moisture present in the
biogas is initially removed because of its presence would be a disadvantage to other cleanup processes.
The theoretical energetic value of biogas with 60% methane content is 5.56-6.64 kWh/m3; in general the
value can be taken 6.5kWh/m3.If this energetic gas is used in CHP-motor, then the conversion process
efficiency must be taken into account. The overall process efficiency can be taken as 30% and the
energetic value of biogas in terms of electrical energy is 1.95 kWh/m3
.
Figure 07: Proposed two stage bioreactor of clean bioenergy production from bio agrowastes

The combined electrical power production of 150 kW electricity by three sources biohydrogen,
conventional biogas and char coal will have energy generation cost of 0.2 US $/kWh. Thus it is again good
proposition to develop district level power production center and along with steam requirement can be
managed by heat recovery from the hybrid fuel cell. The heat required for the reforming is 24 kW is
recovered form the hot spent gas heat recovery management. The hot gas CO 2 separated from the hybrid
fuel cell is circulated indirectly to reduce the char coal to CO for IC engine. The biofuel requirement for the
each fuel cell and char required were tabulated below. The biohydrogen flow rate required for the PEM
cell estimated to be 0.97 m3/hr with two stage tank size of 200 m3 and 12 m3. The new biohydrogen
reactor has benefit in terms reduction in residence time and reduced size in tank by half. The char
required for the IC engine estimated to be 250 kg/hr and

Figure 08: Proposed reduced emission of intergrated system of clean bioenergy production
from bio agrowastes witth co production of feed , fertilizer and methanol

5. Summary and outlook

.
Summary of new scientific results obtained by this work
New ‚renewable power Biohydrgen and biomethanol concepts enable stable renewable power supply and
the use of wind, solar, hydro for long-distance transport and process heat A key element for the integration
of renewable energy into existing supply structures is the ‘renewable power methane’ concept, which has
been developed in this thesis.
Carbon neutral methane ) can be produced by using renewable power, water and CO2 from the
atmosphere or other CO neutral sources like industry and biomass. The main conversion steps are
hydrogen production by renewable powered electrolysis of water, CO2 recovery by a combined absorption
and electrodialysis, and methanation of CO2. Renewable power methane (RPM) allows the transfer and
storage of renewable power in(to) a natural gas network and the flexible use of RPM in all energy sectors.
In the power sector it can be used as balancing power, in the heat supply for process heat and in
transportation as a range extender for electric hybrid vehicles or as liquefied renewable power methane
and renewable fuels from H2 Summary of new scientific results obtained by this work and CO2 (ethanol,
DME, kerosene) respectively in combustion engines and turbines for aviation, navigation, long#distance
traffic and heavy#duty task. RPM is a carbon#neutral substitute for natural gas that can be produced
almost anywhere in the world. In this way, energy demand in industry nations and industrialized regions
can be covered 100% by renewable energy sources.
New synergetic concepts have been developed in this work for the integration of renewable power
methane plants in biogas plants, biomass gasification plants, coal power plants and natural gas sites, CO2
intensive industry, landfills and sewage plants.Using concentrated CO2 from fossil fuels, biomass, waste
or industry processes is more efficient than extracting CO2 from the atmosphere. Nevertheless,
atmospheric CO2 recovery offers the advantages of stand#alone concepts, avoiding long#distance CO2
transportation.
.
Renewable power methanol and energy network integration are key elements of 100% renewable energy
supply structures Energy network integration is another key element of sustainable energy structures.
Linking heat, electricity, natural gas and information networks enables an efficient, almost emission#free
and coordinated use of energy and creates synergy and supply security. Energy management and energy
storage facilities (especially long term energy storage like RPM) will be important elements of future 100%
renewable energy structures along with strong energy transmission capacities.
Major further components of renewable energy structures are efficient end user devices, direct power and
heat generation from renewable sources, renewable electromobility, heat pumps and combined heat and
power generation. The major role in GHG reduction will be played by carbon#free renewables like solar
energy, wind energy and hydro power and energy efficiency measures. Nuclear power plays only a minor
role as nuclear fuels are depleting. Doubling the global installed capacity of nuclear power generation in
20 years doubles associated risks like proliferation, nuclear accidents and waste disposals but reduces at
the most 4% of today’s global GHG emissions given that carbon free nuclear energy is being used.
Strategic use of sustainable bioenergy for overcoming traditional biomass and climate-friendly energy /
material supply avoiding land-use competition and emissions Bioenergy plays a major role in overcoming
inefficient, harmful traditional biomass use that is still the predominating form of global bioenergy use.
Modern bioenergy is a key element of sustainable energy supply in rural regions in developing countries
as Summary and outlook 152 efficiency improvements and GHG reductions can be realized by simple
technology at very low cost. Approximately 0.1 to 0.9 Gt CO2 eq. yr 1 can be avoided in this way.
The global sustainable technical bioenergy potential is estimated at 300 EJ yr#1, the economic potential at
150 EJ yr#1 Residues and surplus forestry show similar potentials like energy crops and are less volatile.
However, the global bioenergy potential is neither sufficient to fulfill the task of balancing power in a 100%
renewable energy supply nor to totally substitute fossil fuels in the transport sector. There are potential
win#win solutions for energy crops in the challenge of land#use competition with food, materials, water
and biodiversity. Planting perennials like sweet sorghum or short rotation coppice on marginal or
degraded land can have an overall positive effect on carbon stocks, and soil and water quality, and avoids
emission# intensive direct and indirect land#use changes as well as displacement risks.
Bioenergy can accelerate or slow down climate change. On one side, exploring the full sustainable
bioenergy potential in combination with low#emission bioenergy pathways, an overall GHG reduction
potential of 2.5 to 16 Gt CO2eq. per year (5#33% of today’s emissions) by bioenergy can be seen. On the
other side, bioenergy can amplify emissions from land#use and land#use changes.
Direct combustion of biomass and co#fermenting manure shows the highest GHG reduction potentials at
highest conversion efficiencies. Electromobility is the most efficient and most climate friendly form of
bioenergy use in transport as long as power and heat sectors are not emission#free or Bio#CCS is
necessary. All positive effects of stationary energy conversion come into effect with electromobility,
powered by biomass: (i) higher conversion rates are achieved by full# load operation, (ii) waste heat can
be used, (iii) by#products like bagasse can be used and (iv) the possibility of future CO2#sequestration is
given. Biofuels in conventional combustion engines are merely suitable for special transport segments
like aviation, navigation and heavy#duty tasks like machinery for agriculture, forestry and construction,
where electromobility hardly can substitute fossil fuels and energy carriers with high energy densities are
required. Oil fruits can be used in this way. All other biomass feedstocks are converted most efficiently to
biomethane via gasification and fermentation that can be used flexibly like renewable power methane.
Outlook on follow#up research topics.
The most suitable parameter for evaluating GHG reduction potentials of bioenergy is the new developed
absolute parameter linking GHG reduction to the chemical energy content of raw biomass. Percentual
parameters do not reflect the amount of biomass or area used for generating one energy unit to substitute
one fossil energy unit. Area# specific GHG reduction indicators have the drawback that hectare yields and
heating values of energy crops differ widely, and these indicators can hardly cover the other main biomass
source: residues and waste.
Bioenergy and renewable power methane are important elements of future sustainable energy supply.
Eventually, the most important strategic function of biomass in the future is the supply of carbon for
industry purposes like chemical products (biomaterials) at the time fossil fuels are gone. Energy supply is
not bound to carbon and can be derived by other means, especially by renewable power as direct power
and as natural gas substitute in form of renewable power methane.
6.2 Outlook on follow-up research topics
This work contributed to the further understanding of possible future sustainable energy systems and
solutions for the integration of (fluctuating) renewable energy and sustainable bioenergy.
Simulation, integration and demonstration of renewable power methane, biohydrgen and biomethanol
concepts .The renewable power methanol (RPM) concepts developed in this work require further
research. In the sintese of methanol using CO2 and hydrogen; optimum catalyst and process parameters
(pressures, temperatures, operation times) are to be identified. Costs need further investigation and
methanol RPM needs to be benchmarked with other long term storage options, network expansion and
other possibilities of decarbonizing the transport sector. The potential of renewable fuel for transportation
from surplus power is to be explored. The demand for balancing power is to be simulated to derive the
demand for RPM and optimum operation scheduling for RPM plants needs to be examined. First pilot
plants are necessary to receive practical results that can be fed back to simulations.
Further development of system modeling and stimulation of system transformation Climate change
mitigation imposes an ample industrial transformation into a pos fossil economy. This system change
requires more than a working GHG emission trading system, which has to internalize external costs of
fossil energy use. Large investments in infrastructure (transport, energy supply) are necessary, which are
not stimulated by increased fossil fuel prices.
Biohydrogen technologies are still in their infancy. Existing technologies are potential for practical
application, but if biohydrogen systems are to become commercially competitive they must be able to
synthesize H2 at rates that are sufficient to power fuel cells of sufficient size to do practical work. Further
research and development aimed at increasing rates of synthesis and final yields of H2 as co products are
essential to make biohydrogen and biogas more competetive with IC engines opertaed with biogas fuel
system.
Computer aided design for biofuelled fuel cells with exiting biogas engines were compared. The Levelised
energy cost to produce 1 kWh Biogas fuelled engine were compared. The integration of combined heat
and power with hybrid engine reduces the cost of electricity production as well as reduction in the
emission. The several process and cost parameters about the viability of this biosystem to make
biohydogen and biogas were obtained and this system has shown to me more promissing to rural
sustainable energy production and local rural developments.
. System design work for decentalized Clean bio energy production for o agroindustrial system are under
study to be implemented in rural are in north east of Brazil.Several computacional models with apropriate
implementing envioronments and several software tool for the system design , analysis and optimization
of the complex sytem design.But the system elements had been sucefully integrated to make possible the
dynamic study of the flux of the matertial , energy and cost to make negry from wastes in an economic.

6.ACKNOWLEDGEMENTS: The authors wish to acknowledge the colaborative join research made
possible with the help from Asia universisty , Thailand and Federal University , UFRN,Brazil and Cnpq,
Brazil.

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ACKNOWLEGMENT: The finanacial support from National Research Council of Brazil
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