Escolar Documentos
Profissional Documentos
Cultura Documentos
TECHNICAL STUDY
The biogas digester is the device in which the digestion processes consist occurs. The
outsource organic manure from cow is called the substrate, and then is diluted with water for also
to prevent clogging the main pipes, and is thoroughly mixed into a slurry. It is then fed into the
digester and permitted to undergo degradation in a sealed oxygen-free chamber with a hydraulic
retention time of 10 days. When digestion is completed, the materials are discharged, or removed
from the digester. The first to be removed is the biogas, it is collected through an accumulator
tank, can now be used as fuel for heating the boiler and the saved fuel undergoes a scrubber for
an increased amount of energy for subsequent use. After the gas is removed, the second material
to be removed by pump is called effluent or sludge.
4.1
Introduction
The company had undergone a careful selection of the process flow. This chapter will
consist of the processes and reactions that will happen within the plant. The plant consists of
processes which includes preparation of raw materials, mixing the diluted manure and passing
through a anaerobic digester for the two products to be collected.
The raw material for biogas production must contain organically bound carbon and
theelement nitrogen which is needed by the bacteria responsible for biogas production. Animal
manure contains a portion of volatile (organic) solids which are fats, carbohydrates, proteins, and
other nutrients that are available as food and energy for the growth and reproduction of anaerobic
bacteria. Cow manure is the commonly used principal raw material, since more biogas can be
generated from cow manures composition. Biogas generation from these wastes has been
proven to be technically feasible, economically viable.1
1 Aakko, P., Jntti, A., Pentikinen, J., Honkanen, T. & Rantanen, L. (2002). An
extensiveanalysis of the exhaust emissions from spark-ignition vehicles using fuels
with
biocomponents. Fisita World Congress 2002. Paper F02E027.
37
38
4.2
Water
ACCUMULATOR
Slurry
DIGESTER
TANK
Water
Raw
Biogas
BOILER
Water
DILUTION
Substrate
SUCTIO
N
Enriched
Biogas
SCRUBBER
DISCHAR
GE
Gas House
Raw
Biogas
SLUDGE
TANK
Scrubbed
Water Line
Pump
Gas Line
Valves
Slurry/Sludge
Line
Sludge
Sludge House
Vessels
4.3
REMOVED
1000 kg water
CO2 (198.86125 kg)
H2S (11.3521365 kg)
H2O (34.0564095 kg)
NH3 (11.3521365 kg)
Total =1,255.62 kg
INPUT
Solid = 2,548.44 kg
Liquid = 14,441.16 kg
H2O = 8,494.8 kg
Total =25,484.4 kg
1000 kg water
OVERALL MATERIAL
BALANCE
RAW BIOGAS
CH4 (681.81 kg)
CO2 (397.7225 kg)
H2S (11.3635 kg)
H2O (34.0905 kg)
NH3 (11.3635 kg)
Total = 1,136.35 kg
OUTPUT
BioMethane ENRICHED
Sludge = 24,348.05 kg CH4 (681.81 kg)
BG = 1,136.35 kg
CO2 (198.86125 kg)
Total = 25,484.4 kg
H2S (0.0113635 kg)
H2O (0.0340905 kg)
NH3 (0.0113635 kg)
Total = 880.73 kg
INPUT = OUTPUT
25,484.4 kg + 1,136.35 kg + 1000 kg = 25,484.4 kg + 880.73 kg + 1,255.62 kg
27,620.75 kg = 27,620.75 kg
Figure 4.2.0 Overall Material Balance
40
4.4
DILUTION
TANK
INPUT
OUTPUT = 25,484.4 kg
Solid = 2,548.44 kg
Diluted Manure
Liquid = 14,441.16 kg
INPUT = OUTPUT
Solid + Liquid + H2O = Diluted Manure
2,548.44 kg + 14,441.16 kg + 8,494.8 kg = 25,484.4 kg
25,484.4 kg = 25,484.4 kg
Figure 4.2.1 Dilution Tank
INPUT = 25,484.4 kg
Diluted Manure
DIGESTER
OUTPUT = 24,348.05 kg
Sludge
OUTPUT = 1,136.35 kg
BG(Biogas)
INPUT = OUTPUT
Diluted Manure = Sludge + BG
25,484.4 kg = 24,348.05 kg + 1,136.35 kg
25,484.4 kg = 25,484.4 kg
Figure 4.2.2 Digester
41
REMOVED
1000 kg water
CO2 (198.86125 kg)
H2S (11.3521365 kg)
H2O (34.0564095 kg)
NH3 (11.3521365 kg)
TOTAL = 1,255.62 kg
1000 kg water
SCRUBBER
RAW BIOGAS
CH4 (681.81 kg)
CO2 (397.7225 kg)
H2S (11.3635 kg)
H2O (34.0905 kg)
NH3 (11.3635 kg)
TOTAL =1,136.35 kg
BioMethane ENRICHED
CH4 (681.81 kg)
CO2 (198.86125 kg)
H2S (0.0113635 kg)
H2O (0.0340905 kg)
NH3 (0.0113635 kg)
TOTAL = 880.73 kg
INPUT = OUTPUT
1,136.35 kg + 1000 kg = 880.73 kg + 1,255.62 kg
2,136.35 kg = 2,136.35 kg
Figure 4.2.3 Scrubber
42
4.5
Stream F
Stream G
Stream A
DILUTION
TANK
Stream C
DIGESTER
SCRUBBER
Stream E
Stream H
Stream D
Figure 4.2.4 Material Balance Process Flow Scheme
Stream A (Wt. of Manure)
Wt. Manure(Solid)= 2,548.44 kg
Wt. Manure(Liquid)= 14,441.16 kg
TOTAL = 16,989.6 kg
Stream B (Water used to dilute)
H2O = 8,494.8 kg
Stream C (Diluted Manure)
Diluted Manure = 16,989.6 kg + 8,494.8 kg
TOTAL = 25,484.4 kg
Stream H (Scrubbed)
REMOVED
1000 kg water
CO2 (198.86125 kg)
H2S (11.3521365 kg)
H2O (34.0564095 kg)
NH3 (11.3521365 kg)
TOTAL = 1,255.62 kg
Stream D (Sludge)
Sludge = 24,348.05 kg
*CH4 (60%), CO2 (35%), H2S (1%), H2O (3%), NH3 (1%) (RICHARD 9).
Target Percent Removal: 99.9 % for H2S, NH3 and H2O, 50% for CO2.
43
4.6
Input slurry (diluted manure) in one day will be completely digested after 10 days
producing total of 69.658 m3or 1,136.35 kg gas based from the material balance
The gas produced per day is uniform in volume meaning 6.9658 m3 or 113.635 kg biogas
is produced everyday.
DILUTION
TANK
A, B, C
X =A+ B + C
44
Solid Balance:
2,548.44 kg = 0.10X
X = 25,484.4 kg
X (Diluted Manure) = A + B + C
25,484.4 kg = 2,548.44 kg + 14,441.16 + C
C = 8,494.8 kg Water (H2O)
C (H2O) = 8,494.8 kg
DILUTION
TANK
A (Solid)= 2,548.44 kg
X (Diluted Manure) = A + B + C
B (Liquid)= 14,441.16 kg
Digestion
Sludge
DIGESTER
X (Diluted Manure)
BG
Biogas Computation:
-Volatile solids (VS) is 91% of total manure solids (RICHARD 10).
-Only 49% of VS is broken down by bacteria (Changet.al., 2006).
-0.0613 m3 gas per kg volatile solid (Chang et.al., 2006).
VS = 2,548.44 kg (.91)
= 2,319.08 kg volatile solid
Amount broken down by bacteria = (2,319.08 kg VS)(0.49) = 1,136.35 kg
45
X (Diluted Manure)
DIGESTER
= 25,484.4 kg
Sludge = 24,318.05 kg
BG= 1,136.35 kg
Diluted Manure
manure = 993.3 kg/m3
H2O = 1000 kg/m3
46
Volume of manure:
= 16,989.6 kg x __1 m3_ = 17.12 m3
993 kg
47
Scrubber
RAW BIOGAS (1,136.35 kg)
CH4 (60%), CO2 (35%), H2S (1%), H2O (3%), NH3 (1%) (RICHARD 9).
Amount of water used in scrubber = 1000 kg water
Target Percent Removal: 99.9 % for H2S, NH3 and H2O, 50% for CO2 .
REMOVED
1000 kg water
CO2 (198.86125 kg)
H2S (11.3521365 kg)
H2O (34.0564095 kg)
NH3 (11.3521365 kg)
TOTAL = 1,255.62 kg
1000 kg water
Scrubber
RAW BIOGAS
CH4 (681.81 kg)
CO2 (397.7225 kg)
H2S (11.3635 kg)
H2O (34.0905 kg)
NH3 (11.3635 kg)
TOTAL = 1,136.35 kg
BioMethane ENRICHED
CH4 (681.81 kg)
CO2 (198.86125 kg)
H2S (0.0113635 kg)
H2O (0.0340905 kg)
NH3 (0.0113635 kg)
TOTAL = 880.73 kg
INPUT = OUTPUT
1,136.35 kg + 1000 kg = 880.73 kg + 1,255.62 kg
2,136.35 kg = 2,136.35 kg
4.8
T1= 25 C
(Ambient temperature)
BOILER
T2= 100 OC
(Boiling point of water)
Q= 105,647.94 kJ/day
T= 48.15OC
P= 0.01MPa
DIGESTER
Q= 170,672.06 kJ/day
T= 24.98OC
P= 3.23 x10^-3 MPa
49
4.9
Stream B
BOILER
Stream C
Stream D
DIGESTER
Stream A
Stream E
BOILER
DIGESTER
x 1000 mol
1 kmol
qwater= mcpT
170,562.25 kJ= (110 kg/hr)(16hr/day)(4.186 kJ/kgK)(T-25)
T = 48.15OC
Therefore the possible temperature that the water can be heated is
T = 48.15OC
Digester Operating Temperature is 48.15OC which is at Mesophilic Range.
4.11 Computation of heat needed for the process.
mass flow rate= 10 kg/hr Water
Cp=4.186 kJ/kg-K
Latent heat= 88kJ
T1= 25 OC (Ambient temperature)
T2= 100 OC (Boiling point of water)
Q=mCpdT + latent heat
Q=110 kg/hr(16 hr /day)(4.186 kJ/kg-K)(100OC 25OC) + 88 kJ
51
Q= 552,640 kJ/day
Latent heat= 88kJ
m= 10 kg/hr Water
Cp=4.186 kJ/kg-K
T1= 25 OC
T2=100 OC
Note: Using thermodynamics properties of water to get the pressure of the steam from calculated temperature.
Considering 50% heat loss from 552,640 kJ/day
Q=276,320 kJ/day in entering pipe
T2= 100 OC
Q=mCpdT
276,320 kJ/day = 110 kg/hr(16 hr /day)(4.186 kJ/kg-K)(100 OC T1)
T1= 62.49 OC
Note: Using thermodynamics properties of water to get the pressure of the steam from calculated temperature.
4.12
Given:
6.9658 m3 BG/day
Basis: 1 hour
Solution:
6.9658 m3 BG x 0.6 parts CH4 x _1kg CH4 x 1 kmol CH4
x 1000 mol
1 part BG
0.68 m3CH4
16.043 kg CH4
1 kmol
= 383.11 mol CH4
Hrxnmethane = -890.4 kJ/mol
q = -890.4 kJ/mol CH4 (383.11 mol CH4)
= -341,124.50 kJ
considering heat loss of 50%,
Since qmethane= qwater,
qwater= mcpT
170,562.25 kJ = (110 kg/hr)(16hr/day)(4.186 kJ/kgK)(T-25)
T = 48.15OC
Therefore the possible temperature that the water can be heated is
T = 48.15OC
T= 48.15 OC
DIGESTER
Q=mCpdT
Q=110 kg/hr(16 hr/day)(4.186 kJ/kg-K)(62.49OC 48.15OC)
Q= 105,647.94 kJ/day
Q=105,647.94 kJ/day
T= 48.15 OC
P= 0.01 MPa
Considering 50% heat loss
Q=276,320 kJ/day in entering pipe
T=62.49 OC
P= 0.02 MPa
Q= 105,647.94 kJ/day
T= 48.15 OC
P= 0.01 MPa
DIGESTER
Input=Output
53
Q= 105,647.94 kJ/day
T= 48.15 OC
P= 0.01 MPa
DIGESTER
Q= 170,672.06 kJ/day
T= 24.98 OC
P= 3.23x10^-3
54
4.13
Water Line
Gas Line
Slurry Line
56
4.14
Equipment Design
This part shows the design and specifications of the equipments including the type, dimensions, the pumps, pipes, and fittings;
the material handling; the instrumentation and process control; and the equipment flow diagram of the proposed project.
VACUUM RELIEF
MANHOL
E
DILUTED
MANURE
WASTE GAS
BURNER
GA
VALV
E
VALV
E
AGITATO
R
PUMP
6-8
SLUDGE
SOLIDS
6-
SLUDGE
DRAWOF
F PIPE
SLUDGE
STORAGE
TANK
The digester tank is a completely enclosed concrete tank covered by an airtight seal. The tank can be fitted with heating coils
that warm the digesting biomass. The tank is equipped with a stirrer that can keep the entire volume fully agitated and thus prevent the
formation of a surface crust. It is also equipped with an over-flow outlet, temperature and pressure gauges, etc. There is, finally, a
high-pressure valve to ensure that the pressure does not become unacceptably high if the gas removal fails. At the top of the tank there
is an outlet for the biogas produced. The reactor tank typically has a volume of 10-20 times the daily input of biomass for a
thermophilic process and 15-25 times the daily input for the mesophilic process.
4.15
Summary
Wall Thickness
Interior = 4
Volume of digester
= Vd :=Sv + (Sv)(.50)
Exterior = 3
Hbody= 2 m Slurry Holder
A= 19.2 m2
r= 2.47 m
Gas Holder
Configuration: Cylindrical
Htop= 2 m
Height of digester = 2 m
V= 38.4 m3
2
V= r h=Ah
38.4 m3=(A)*(2m)
Area of digester = 19.2 m2
58
A= r
2
19.2 m2= r
r= 2.47 m
Volume of biogas = Vb := 69.658 m3 + 69.658 m3(.50)
with (50%) allowance = 104.49 m3
Dome:
V= /2ha2
w/r: a= 19.2 m
59
4.16
Configuration= Rectangular
V=(L)*(W)*(H)
L=W
36.61 m3=(L) *(W)*(H) w/r: H=2m
36.61 m3=(L)*(W) *(2)
L=W= 4.27 m
Figure 4.5.1 Slurry Storage Tank
Wall Thickness
Exterior= 2
Interior= 1
L= 4.27 m
H=2 m
60
W= 4.27m
A= 18.23 m2
V= 36.61 m3
4.17
= 38.41 m3
Wall Thickness
Exterior= 4
Interior= 2
L= 3.57 m
W= 3.57 m
61
H= 3 m
A= 12.75 m2
V= 25.61 m3
4.18
r= 0.66 m
A= *(0.66)2= 1.37 m2
Figure 4.5.3 Boiler
Hbody= 1.5 m
A= 1.37 m2
r= 0.66 m
Htop= 0.2 m
V= 1.76 m3
62
4.19
r = 3.33 m
Htop= 0.5 m
V= 69.658 m3
4.20
Configuration: cylindrical
m(entering water)= 1,000 kg
Density=mass/volume
1000 kg/m3=1,000 kg/V
V= 1 m3
Volume with 20% allowance= 1 m3+ 1 m3*(.20)
Volume with 20% allowance= 1.2 m3
V= r2h w/r: h= 3 m
r= 0.36 m
A= *(0.36)2= 0.40 m2
Figure 4.5.5 Scrubber
Hbody= 3 m
A= 0.40 m2
r= 0.36 m
Htop= 0.2 m
64
Hbottom= 0.2 m
4.21
Wall
Thickness
(inches)
7
Mixing Tank
Boiler
Sludge Storage
Tank
Accumulator
Scrubber
Configuration
Area
(m2)
Radius
(m)
Total Height
(m)
Cylindrical (body)
w/
Top and Bottom
Dome
Rectangular w/
Top Opened
Cylindrical (body)
(aluminum)
w/
Top Dome
Rectangular w/
Top Opened
Cylindrical w/ Top
Dome (aluminum)
Cylindrical
19.2
2.47
12.75
1.37
0.66
18.23
Width
(m)
Length
(m)
38.4
3.57
3.57
1.7
Volume
(m3)
25.61
1.76
4.27
4.37
36.61
34.8
3.33
2.5
69.658
0.40
0.36
3.4
1.2
65
4.22
needing such aide for transporting from one process to another are easy to handle, thus, motor
pumps will give remarkable and efficient aide.
The materials used for the pipes for different unit operations were preferably
Polyethylene pipe with 50.95mm for the main production line and 20mm for the other
transferring of fluid and natural rubber for the transportation of gas. Since the input is corrosive
the pipes are effective to be used.
The pipes, valves and fittings needed for the production with the specification can be
bought locally.
For one working digester set-up.
Table 4.7.1 PIPELINE LIST
Material
Polyethylene Pipe
Polyethylene Pipe
Natural Rubber
Polyethylene Pipe
Natural Rubber
P-1
P-2
P-3
P-4
P-5
Diameter
50.95 mm
20 mm
20 mm
50.95 mm 1.40 m
20 mm
Length
0.40 m
1.40 m
0.40 m
1.40 m
2m
4.23
Line Size
20 mm
20 mm
Valve/Fitting Class
Gate Valve
90 degrees
Material Handling
The cow manure required each day is 16,989.6 kg of operation will be collected at
different location near the plant, whereby, it will be recommended to know the closest
source of cow manure will be and the class of manure which must not been contaminated
e.g. soil, sand, and must only be from cows. Then the collected cow manure will be
directed to dilution tank, the dilution of manure will also prevent clogging the main pipes
when the operation starts, the amount of water used in dilution of manure is 8,494.8 kg
water. The required manure and calculated amount of water used is in dilution are in
detailed computation.
Sludge
When the gas have been collected the sludge will be pumped out from the bottom of the
digester and the collected sludge from the tank will be sent to the sludge house which can
be used for potential application in the fields. Careful handling and storage of raw
materials are based mainly to the amount of product produced each day.
Gas
After the gas have been collected from the accumulation tank that has lower energy value
for transport fuel needed it will be directly sent to the scrubber made with the
specification needed for the entering gas and amount of water to be used, the converted
gas will pass through a compressor for an efficient use that will be collected in vessels
provided and the vessels used will be stored in the gas house.
*The pump can be im-mersed in the dilution tank or sit in its own pump well. The pump often
has an associated comminutor, which shreds the biomass.
67