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MARCH 2017
ABSTRACT i
LIST OF FIGURES iii
LIST OF TABLES iv
CHAPTER 1: INTRODUCTION 1
1.1 Background Study 1
1.2 Problem statement 2
1.3 Objective s 3
1.4 Scope of study 3
LIST OF TABLES
INTRODUCTION
The main constituents of biogas are methane (CH4) and carbon dioxide
(CO2) along with some traces of gases such as water vapour, hydrogen
sulphide (H2S), nitrogen, hydrogen and oxygen (Deublein & Steinhauser,
2010). Biogas is simply being flared due to its undesirable low calorific value
for conventional combustion purpose and causes a waste of potential
renewable energy source. Palm oil mills has started to employ mechanisms to
capture the methane emitted from their treatment ponds and utilize it as one of
energy source for combustion in their boilers and gas generators. Developed
countries all over the world has been utilizing their biogas produced from many
sources such as energy crops, animal waste and municipal solid waste for a
higher end uses such as vehicle fuels and injecting into natural gas grids to
generate electricity. Impurities and traces gases must be removed because the
hydrogen sulphide gas is corrosive and water vapour may cause corrosion
when combined with H2S on metal surfaces including pipelines, reduces the
heating value and causes maintenance problems (Kadam & Panwar, 2017). It
is important to remove the water before using the biogas as slugs of water can
damage gas compressors for example and it can also reduce the efficiency of
CHP engines. In order to function well with energy efficient systems like the
way compressed natural gas (CNG) has been utilized, various upgrading and
cleaning methods need to be applied in order for the biogas to work efficiently
and compatibly with the energy efficient systems. Many separation
technologies has been applied mostly by the means of water scrubbing, and
chemical absorptions which might consume a lot of energy especially when the
chemicals are required to be heated or the equipment are consuming electricity
to operate. This project tries to investigate the feasibility to upgrade or purify
the biogas produced from selected plants.
1
Focus will be put on physical method of removing water from raw biogas
by using a supersonic centrifugal separator which has been used widely in
oilfield application to separate water from natural gas.
One of the obstacles faced by biogas plants is the impurities and water
content in the biogas which could lead to problems such as corrosion of equipment,
lowering the heating value, ice-clogging and accumulation of condensate in the
gas line. Thus the problem statement is summarised as:
2
1.3 Objectives
3
CHAPTER 2
4
Review of the preceding elements are then assembled into a Feasibility Study
which serves two purposes: to substantiate the thoroughness and accuracy of the
Feasibility Study, and to make a project decision; either approve it, reject it, or ask that
it be revised before making a final decision. In this project, the best approach and sets
of parameters in order to produce the expected or desired separation performance chart
will be determined. If the Feasibility Study is rejected, the reasons for its rejection
should be explained.
5
In another study, a novel design methodology for the feasibility and technical
evaluation of reactive distillation (RD) is presented where a framework for the
feasibility evaluation which leads to the determination of boundary conditions,
integrated process limitations is proposed (Shah et al., 2012). An overview of the state-
of-the-art methods are available in the literature for the feasibility analysis and design
of reactive distillation processes where the synthesis design method is used to conclude
the feasibility of applying the technology and the process limitation is identified
therefore the model that could fit the simulation study can be chosen (Thery et al.,
2005). A feasibility study could be proven by experimental method or by carrying
simulations. Therefore in this project, the boundary conditions for the simulation
process is introduced and the process limitations are identified as it is one of the most
significant information required for evaluating design parameters in a feasibility study.
2.2 Biogas
The impurities could cause problems such as corrosion, toxicity and reduction
of heating value if not treated or refined. The refining process could be classified into
two categories, primary refining describes the treatments of the raw material, whereas
secondary refining includes processes and treatments for upgrading the biogas for
application onto energy efficient systems. In order to utilize the biogas for high end
use such as injection into natural gas grid or as vehicle fuel, two major steps are
performed: (1) cleaning process to remove trace components and (2) upgrading
process to adjust the calorific value (Ryckebosch et al., 2011). Generally, biogas bio
refineries consist of three main units: The substrate reception including pre treatment
and feeding equipment, the digestion unit including one or more gas tight and heated
anaerobic tanks connected by a biogas collection system and lastly the digestate
storage and possibly post treatment units (Lindorfer & Frauz, 2015).
6
According to statistics Malaysia produces around 42.3% of worldwide palm
oil. In a survey made in 2012, there are 426 palm oil mills throughout Malaysia
however only 12.9% have a complete biogas plant integrated in their mills while 3.8%
is under construction while a majority of 35.2% is still under planning. This indicates
that only about half palm oil mills in Malaysia utilized the potential of their palm oil
mill effluent as source of renewable energy while the remaining half chose the
conventional ponding system and open tank digestion system where the methane gas
is simply released into the atmosphere (Abdullah & Sulaim, 2013). The growth of
biogas installation in palm oil mills is relative slow due to high investment risk and
long payback period.
Most agricultural biogas plants ferment liquid manure and even combine them
with co-substrates to enhance biogas yield. The choice of feedstock also contributes
for composition of biogas and methane yield. The table below describes the typical
biogas composition based on different feedstock.
Table 1
Component Unit POME Sewage Landfill
biogas plant
CH4 vol% 6070 5565 4555
CO2 vol% 3040 3545 3040
N2 vol% <1 <1 515
H2S ppm 102000 1040 50300
7
(Basri et al., 2009) stated that since palm oil is one of the most common agricultural
industry contributor in Malaysia, palm oil mill effluent (POME) is chosen as the main
feedstock to generate biogas rather than other biomass and crop waste sources and
landfills which utilized in other countries. For European countries like Denmark, their
main biogas resources is manure due to their high animal production (Bruni et al.,
2010).
Since the main emphasize in this project is to study the performance of water
separation from biogas, it is important to know the quality of biogas targeted for each
utilization and application. Raw biogas composition is primarily methane (CH4, 40-
75%) and carbon dioxide (CO2, 15-60%). Trace amounts of other components such as
water (H2O, 5-10%), hydrogen sulphide (H2S, 0.005-2%), siloxanes (0-0.02%),
halogenated hydrocarbons (VOC, < 0.6%), ammonia (NH3, <1%), oxygen (O2,0-1%),
carbon monoxide (CO, <0.6%) and nitrogen (N2, 0-2%) can be present (Wellinger &
Lindberg, 2005). Weiland also mentioned that biogas is saturated with water and need
to be dried and desulphurizated to prevent damage to the gas utilization unit. The
general purpose of modifying, purifying or cleaning the raw biogas is to increase the
calorific value and reduce unwanted components, e.g. CO2 and H2S, which are harmful
to utilisation systems (Tippayawong & Thanompongchart, 2010). Upgraded biogas
which contains more than 90% methane has approximately the same quality as natural
gas and can be injected to gas grid, applied as a fuel in CHP generation or utilized as
vehicle fuel (Taleghani & Shabani Kia, 2005).
Currently, biogas is mainly used for: (1) burning biogas in a combined heat
and power (CHP) unit to generate heat and electricity; (2) upgrading biogas for natural
gas pipeline injection; and (3) converting purified biogas to compressed biogas (CBG)
or liquid biogas (LBG) for variety of fuel applications (Yang et al., 2014).
8
A survey carried on Clean Development Mechanism (CDM) registered palm oil mills
in Malaysia, so far the biogas produced is only utilized in boiler and gas engines with
majority of the plants choosing to simply flare the bioenergy source due to relatively
low emission of methane in covered ponds (Chin et al., 2013). High gas quality is not
required for boilers and combined heat and power (CHP) generation and biogas can
be applied directly in these technologies (Hosseini & Wahid, 2015) although H2S level
must be lower than 250ppm to prevent excessive corrosion in the equipment (Weiland,
2010). Only vapour and H2S removal is needed to be used for heat and electricity
production however, a relatively higher concentration of CH4 and removal of most
impurities is necessary for biogas to be applied as vehicle fuel and pipeline injection
applications, instead of only to be injected into natural gas grids (N., 2008).
For application of biogas into energy efficient systems such as vehicle engines
it is mandatory to upgrade it up to compressed natural gas (CNG) quality. The methane
content must be more than 97%, CO2 less than 3% by volume,H2S less than 10 ppmv
and water content should be less than 32mg/Nm (Najafpour et al., 2006). (Wellinger
& Lindberg, 2005) has indicated the gas quality requirement for France, Switzerland
and Sweden where for vehicle fuel utilization, water content must be less than
100mg/nm, 5mg/nm and 32mg/nm respectively. A company called Novaviro Sdn
Bhd provides technology for biogas plants implementation claimed that their
dimensioned plants is able to meet the gas specification requirement stated earlier.
A BioCNG plant located at the Felda Palm Oil Mill Sg. Tengi, Kuala Kubu
Bahru, in the state of Selangor is upgrading raw biogas from composition of 60% CH4,
35% CO2 and 3000 ppm H2S to BioCNG or Renewable Natural Gas of > 94% CH4
content. The BioCNG is then compressed to 250 bar and dispensed into CNG trailers
to be sent to factories. According to U.S. pipeline specifications, natural gas pipeline
injection requires purified biogas that contains CO2, water,and H2S at less than 3%,
112mg/m3, and 4ppm, respectively (Graf, 1987). Bio-CNG conversion requires
purified biogas with higher than 97% CH4. For liquefied biomethane
production,biogas has to be purified to contain less than 25ppm, 4ppm, and 1ppm of
CO2, H2S, and H2O, respectively, to prevent dry ice formation and corrosion (Brown,
Shi, & Li, 2012). (Persson, 2003) stipulated that the most common technology for
water removal is adsorption on the surface of a drying agent such as hygroscopic salts,
zeolites, silica gel or aluminium oxide.
9
From the data tabulated by (Ryckebosch et al., 2011) the concentration of CH4
has to be increased to almost 100% in order to replace natural gas in domestic stoves
without any retrofit. Another study mentioned that upgraded biogas which contains
more than 90% methane is interchangeable with natural gas and can be applied to gas
grid, as a fuel in CHP generation or utilized as vehicle fuel (Taleghani & Shabani Kia,
2005) whereas to be used as alternative fuel, the raw biogas must be upgraded to more
than 95% methane content (Navaratnasamy, 2008).
In a nutshell, biogas can be used as fuel for domestic stoves, boilers, internal
engines, gas turbines, vehicles and fuel cells, or injected into natural gas grids to
replace gaseous fuel. Not all utilizations require biogas to be purified into biomethane
quality. The table below describes the requirements for impurities removal for few
applications. This gives an idea that the biogas water removal is only required for
vehicle fuel and natural gas grid injection application therefore based on the water
separation performance obtained, it can be concluded whether the water content
reduction by using supersonic centrifuge would be beneficial or not.
10
Most biogas cleaning methods are derived from conventional gas separation
technologies and many of them have been success- fully applied for natural gas
purification (Makaruk et al., 2010). It was found that chemical absorption is the best
suited biogas-upgrading technology due to high requirement of methane purity and
energy efficiency for example when to be used with domestic stoves. Technology such
as water scrubbing, physical adsorption, pressure swing adsorption and membrane
technology are more suited when the methane purity requirement is lower. Iron oxide
or iron hydroxide is used to remove H2S to less than 1ppm while biological
desulphurization will remove H2S to less than 50ppm for combined heat and power
(CHP) use such as boilers (Hosseini & Wahid, 2015).
11
Impurities such as CO2, O2 and H2O passes the membrane as permeate while low
permeable CH4 is retained and collected. This method is known for its safety, scale-up
capability, simple operation and maintenance and no involvement of harmful
chemicals. The methane purity yielded from this process ranging from 90% to 96.5%
with average of 90.3% from most membrane separation plants, and this number is
lower than that yielded from pressurised water scrubbing, pressure swing absorption
and chemical absorption (Yang et al., 2014). Membranes also could be used for
removal of other impurities such as water vapour since they are highly water-
permeable (Ohlrogge & Brinkmann, 2003) however there is no specific details or study
made on the effectiveness of water removal by this technique.
12
It is important to remove water and control its amount at a low level to reduce
the risk of wet compression and condensation of flue gas when used in turbines. Main
purpose for removal of water is to prevent accumulation of condensate in the gas line,
and formation of corrosive solution when H2S is dissolved and to achieve low dew
points when biogas is stored under elevated pressures to avoid condensation and
freezing. It is also advised to condense the water vapour in the raw gas as water vapour
can cause problems in the gas nozzles. Removal of water will also remove a large
proportion of the H2S, reducing the corrosion and stack gas dew point problems
(Wellinger & Lindberg, 2005).
Table 3: Requirement on biogas quality and technological recommendations for biogas utilizations
13
Natural gas grid 70 98 1.0 - 8.0 H2S: 2 15mg/m CO2: PSA and
injection O2: 0.001-3% (mol) membrane if O2
N2: 2 10% (mol) and N2 removal
H2: 0.1 4% (mol) needed; chemical
absorption and
PSA if high CH4
purity needed
H2S: impregnated
activated carbon
and iron
hydroxide/oxide
(Ryckebosch et al., 2011) has reviewed the techniques for removal of water
from biogas which can be categorised as physical drying and chemical drying methods
which can be summarised as below:
Condensation method Higher HCs dust and oil are Atmospheric pressure: dew
Demister removed point minimum 1 C
Cyclone Simple techniques Gas at higher pressure to reach
Moister trap Often used as pretreatment lower dew point (minimal 18
Water taps before other techniques C) but freezing can occur
Adsorption dryer Silica High removal: dew point 10 More expensive investment :
Aluminum till 20 C pressure 610 bar
Low operational cost Dust and oil need to be
Regeneration possible removed in advance
Absorption with glycol High removal: dew point 5 till More expensive investment:
15 C high pressure and 200 C for
Higher HCs and dust are regeneration
removed Higher gas volumes (>500
Not toxic or dangerous m3/h) to be economical
14
As shown in the table, cyclones is known as one of methods that is suitable for removal
of water from biogas. The concept of cyclones was introduced to the oil and gas
industry and used as one of methods for dehydrating natural gas in 1990s. These
separators were known as reliable devices due to no rotating parts, required no
chemicals and were capable of unmanned operation. Typically the device removes
water vapour to control the dew point of the gas. The following is a brief review of the
achievements of these studies.
15
A supersonic separator mainly consists of four parts, known as the swirling
device, a Laval nozzle, a cyclonic separation section and a diffuser. The swirl device
transforms part of the axial velocity to angular velocity and generate swirls. The Laval
nozzle accelerates the natural gas flows until sonic speed is obtained at the nozzle
throat. In the divergent part, the natural gas is further expanded to supersonic velocity
resulting in a low pressure and temperature, which this condition encourages the
condensation of water vapour. The cyclonic separation section is located at the
extension of the Laval nozzle. It provides enough space and time conditions for the
separation processing in supersonic velocities. In the diffuser, the supersonic velocity
is reduced to subsonic when the natural gas flow meets the shock wave.
Hence, the diffuser transforms the remaining kinetic energy to pressure for energy
saving (Wen et al., 2015). Since the gas mixture is flowing at supersonic velocities,
residence time is extremely low in this type of separators and hydrate has no time to
deposit along the device thus eliminates the need for inhibitor injection. The unit is
considerably more compact than conventional dehydration units and therefore suitable
for offshore applications (Brouwer et al., 2004). Moreover, the nozzle has no moving
parts and is simple to operate which makes it a very good candidate for unmanned
operations (Brouwer et al., 2004 and Schinkelshoek, 2006) for subsea application. It
is also important to note that the gas temperature is reduced based on gas expansion
principles and requires no external refrigerant. This brings another major advantage
over conventional dehydration units in that intensive water dew points, down to -60C,
can be achieved without any use of external cooling (Karimi & Abdi, 2009).
16
He determined the compositions of gasliquid mixtures are determined as a function
of the initial parameters (composition of gas, temperature, pressure, and Mach
number). This method where the results are given in the form of temperature, pressure,
and Mach number dependences of the composition of the liquid phase of gasliquid
mixture could be applied in this project in order to investigate the separation efficiency
of biogas and water composition hence determines the feasibility of using the biogas
with the separator. Qingfen, Depang, and other colleagues (Qingfen et al., 2009)
investigated the performance of supersonic separators incorporating a method of
particle enlargement to reduce the length of the device where air-ethanol is used as
their medium and water droplets as nucleation centers.
17
(Arina, 2004) tested three state equations which are Van Der Walls, Carnahan-
Starling-De Santis (CSD) and Redlich Kwong (RK) and found that real gas model is
more in-line with prediction of the theoretical model. Therefore a type of real gas
model will be adopted during the simulation in this project to provide a more realistic
simulation.
Based on the brief review of the achievements above, it can be noticed that
supersonic separators has been widely studied and utilized mainly for purification of
natural gas. However, there are no detailed studies or tests conducted on the
performance and capability of cyclonic seperation devices in dehyrating biogas which
has a significant difference in gas composition compared to that of natural gas.
Therefore it is important to study and evaluate the feasibility of seperating water from
biogas and the possible changes in input parameters in order to make it works.
18
CHAPTER 3
METHODOLOGY
The main target of this research is to explore the performance and the outcome
of using a centrifugal separator developed by UTP Gas Separation Research Centre to
remove water from palm oil mill effluent-derived biogas. It is important understand
the existing processes and technologies for separating water from hydrocarbon gas,
especially cyclone type separator which originate from separation techniques done in
the oilfield industries. The sample biogas specification will be studied from visits made
to biogas plants. However if the permission for the industrial visit is not approachable,
the biogas specification will be chosen based on the literature review and past
researches. Stages of biogas purification usually start with H2S removal followed by
water removal depending on the requirements. The effect of different biogas
composition on the separation performance along with other operational parameters
will be explored.
19
3.2 Project flowchart
3.2.1 Overall project flowchart
The project will be conducted according to the process flow chart below:
20
3.2.2 CFD simulation flowchart
Design methodology which adapted from Pahl and Beitz could be divided into
5 phases namely the Design Specification Development, Design Concept
Development, CAD Model Development, CFD Simulation and Optimization and
Technical Drawing. In this project, phase 1 until 3 of the design methodology and
the pre-processing step for the simulation is covered by importing the supersonic
separator 3D model and design parameters from the existing prototype model
developed by UTP Gas Separation Research Centre. Currently the prototype has been
successfully tested for natural gas dehydration. Phase 4 of the design methodology is
shown in the flowchart below where is the CFD simulation and optimization will be
covered in this project.
OPTIMIZE
Supersonic Flow Character-Supersonic
Compact Wet- Diverge
Gas Separator Nozzle Angle vs Fluid Flow
Supersonic
Variation Pressure Vs Temp. compact Wet-Gas
Separator Converge
Water Separation Performance
21
Defining a system involves identifying the equations that describe that system,
such as mass and momentum conservation equations, as well as physical properties of
the fluids at different conditions. Solving these equations simultaneously and closing
them with the appropriate boundary conditions is usually referred to as the processing
stage. In the processing step of the simulation, the geometry will be introduced into
the numerical solver where the equation of state, turbulence model, solution algorithm
and convergence criteria, boundary condition, material properties and simulation
parameterization will be done.
22
The finite volume method will be used for mathematical calculation, and the
second-order upwind scheme and wall function will be integrated along wall while for
the pressure and velocity coupling, semi implicit method or SIMPLE algorithm will
be selected in the in the solution methods menu in Fluent (Patankar, 1980). The
scheme will solve the momentum equations by predicting the pressure gradient and
getting a convergence.
Boundary conditions are used to define the known limits of the system. In the
systems studied here, three regions have to be defined are the nozzle inlet, nozzle outlet
and nozzle walls. The inlet will be defined as a Pressure inlet, which uses the pressure
and temperature of the gas at the inlet as a constant and adjusts other parameters such
as velocity and flow rate accordingly.
Mass flow inlet was also used in some simulations to evaluate the effects of
flow rate variations. This condition assumes the mass flow rate and temperature as a
constant and adjusts the other parameters such as pressure and velocity
correspondingly. The outlet is always modelled as a Pressure outlet where the pressure
and temperature of the gas are defined at the outlet. The walls are always modelled as
a smooth and insulated surface where no flow of energy takes place. This is consistent
with the theoretical assumption of an adiabatic expansion of the gas.
The post-processing section explains the techniques and properties that were
used to analyse and compare the solutions obtained from the CFD simulations. The
properties that were used to evaluate the performance of the separator design include:
maximum velocity achieved in the device, centrifugal acceleration, position of the
shockwave, pressure loss, mass flow rate, residence time, and separation length. All
the above mentioned properties will be reported in form of tables, graphs, contours, or
vector plots as suited by the nature of the property and analysis methods.
23
Week
Details of Activity and Key Milestone
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
PROJECT PREPARATION AND FAMILIARIZATION
Perform preliminary research
Research and literature review of project
Study the biogas production process and upgrading technology
Industrial visit and identify sample composition
3.3.1 Gantt Chart
COMPLETION OF RESULTS
Evaluation of separation efficiency
24
Catia modelling
Ansys Fluent simulation
Collection of data and analysing results
Collecting results from simulation
Analysing the results
DATA ANALYSIS AND DOCUMENTATION
Drawing conclusions and recommendations
Identifying the significant parameters
Concluding and final compilation
The proposed Gantt Chart for this project is shown in the figure below.
The overall project key milestone is shown in the table below which describes
significant achievements that are expected from this final year project.
25
CHAPTER 4
The biogas flow field will be simulated in the compact wet-gas separator based
on the numerical methods as mentioned in the methodology. Variables such as static
temperature and tangential velocity of cross section and mach number at the nozzle
will be analyzed along the axis. In the compact wet-gas separator, the fluid which is
biogas expands in the Laval nozzle to supersonic velocities with the Joule Thomson
effect thus lowering the temperatures. The static temperature diminishes gradually in
the convergent segment of the nozzle, while expansion of gas initiates a fast decrease
in the divergent part. The results expected from this experiment will be in the form of
resulting mass fraction composition obtained from the outlet of the separator. As
mentioned earlier, the inlet working fluid for the raw biogas will be simulated in form
of methane, carbon dioxide, water and hydrogen sulphide which takes 64%, 30%, 5%
and 1% of mass fraction respectively. The water separation efficiency could be
calculated by comparing the difference in mass fraction of liquid particles passing
through the liquid outlet slit located at the nozzle of the separator and the mass fraction
of liquid particles passing through the dry gas outlet. The velocity, pressure and
temperature contour could also be extracted from the simulation and the data will be
analysed accordingly until the best working condition and separation efficiency is
determined.
26
CHAPTER 5
Based on the expected results explained earlier, the project has been progress
according to the timeline that has been suggested in the Gantt-chart. The
familiarization stage with the Fluent software has been done allowing the
understanding of how the results could be represented hence concluding that water
separation from biogas is feasible. Since this project is mainly on investigation of
possibility of utilizing the currently available Compact Wet Gas Separator prototype,
variables such as the dimensions of the model such ratio of the length of the cyclone
separation section to the diameter of the wall at throat is fixed. Therefore the variables
that could be altered in order to achieve the best working condition of the medium
fluid inside the separator is the velocity, temperature, pressure and mass fraction of the
composition of the working fluid.
After the results had been obtained, the project can be continued and focused
on repeating the simulation with different inlet boundary conditions until the best
separation efficiency possible is obtained.
27