Biogas Application

Engine IQ

Distributed Power
August 2016

Imagination at work
Fuel flexibility
Range of gases used in Jenbacher gas engines

Low heating values are not critical for suitability in our gas engines
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LEANOX® - Lean-burn combustion control

Advantages
•Sensors in non critical
measurement ranges
(pressure, temperature,
deposits...)

•Reliable and durable

compliance with exhaust
emission limit at changing
operational conditions
(fuel gas compositions...)

•Controlled combustion
and subsequently
controlled stress of
various components
(valves, cylinder heads,
spark plugs...)

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Jenbacher SPARK PLUG

Characteristics
• Efficient & reliable combustion
• Low emission (NOx)
• Enables high specific output

Advantages
• Low specific spark plug cost
• Long regapping interval
• Low emissions
• High Reliability

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Biogas Plant – typical solution

GE scope ~35% of total biogas plant capex:

Jenbacher engine, heat exchangers, generator

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Source: GE Jenbacher/KWE 25.01.2017
Heat utilization in Biogas-CHP
JMS 312 GS-B.L (C225)

Electr. Output: 526 kW

Recov. Heat: 524 kW
LT-IC heat: 23 kW

Therm. Efficiency: 40,3%

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Propane gas for Biomass digestion

For heating up the fermentation process which last several weeks we can operate the engine with
propane gas.

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Biogas

> 4,290 Jenbacher biogas engines >3,000 MW worldwide

• Anaerobic digestion produces fuel gas
• Renewable – from organic and animal waste
• 7,000 cows can power 1 MW plant

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Investment and Cost of electricity basis

Investment costs based on European figures Initial cost of electricity

500 1000
Contenerized Biomass input
kW kW
CHP plant
95% manure ~ 10 ~8
35% 2/3 energy crops
(Corn cost: 35 €/t)
~ 15 ~ 13

65% palm oil mill effluent

(Asia)
~6 ~4

€cent/kWhel:
• 8000 operation hours per year
• Financing based on 10 years
Biomass preparation,
digester, gas holder…

1000 kWel. Plant

approx. 2,500 – 3,000 € per kW
Palm oil:
• Input material for free
• No fermentation invest ->
lagoon which has to be covered
• Simple fermentation technique

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Biogas – Cost of Electricity

Segments
Cost of kW
1) Energy Crops 16,00

14,00
Fuel
2) Agricultural Waste 12,00 13,19
Service BoP
10,00

€ Cent / kWh
Service Genset
9,64
8,00
3) Municipal Waste Investment BoP

Investment Genset
6,00
5,62 Thermal Savings
4,00
CoE
2,00

0,00
Energy Crops Agricultural Waste Municipal Waste

Electrical Oph 8000 8000 8000

(oh/y):

Thermal Oph 4000 4000 4000

(oh/y)

Gas tariff: .03 €/kWh Free free

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© 2016 General Electric Company - All rights reserved
Operational conditions of the fermentation
process
waste wheat
waste bread
grease trap contents
corn-cob-mix
corn silage
grass silage
food waste
municipal biowaste minimum
brewery variation
beet
grass cuttings
potato peelings
pig manure
cattle manure
0 100 200 300 400 500 600 700
Standard m³ biogas / ton

Gas mixture composition: • Temperature

50 – 70% methane (CH4) - mesophile process: 35 - 40°C
30 – 50% carbon dioxide (CO2) - thermophile process: 50 - 55°C

Dry matter concentration • Retention time

- dry fermentation: 20 - 30% - minimum 15 days
- wet fermentation: 10 - 15% - range: 20 - 50 days
• Absence of oxygen - common: 25 - 30 days
• pH value from 6.5 to 7.5
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Animal waste
Energy potencial Advantages of anaerobic digestion

For the Farmer

1 Live Stock Unit (LSU) = 500 kg live weight respectively • Improvement of manure
properties: odor reduction,
elimination of acid components,
1 LSU = 0.6 - 1.2 milking cow
viscosity decrease, mineralization
approx. 1.3 m³ Biogas/LSU, day
of organic nitrogen, reduction of
LHV = approx. 6.0 kWh/Nm³
pathogenic germs and weed seeds
~7,000 cows = 1 MWel
• Additional income from heat and
power production
1 LSU = 2 - 6 hogs
approx. 1.5 m³ Biogas/LSU, day
For the Environment
LHV = approx. 6.0 kWh/Nm³
• Reduction of methane and
~70,000 hogs = 1 MWel
ammonia emissions from manure
• Reduction of nitrate wash-out into
1 LSU = 250 - 320 layers
groundwater
approx. 2 m³ Biogas/LSU, day
• Recycling of fertilizer compounds
LHV = approx. 6.5 kWh/Nm³
from organic wastes
~1.4 million layers = 1 MWel
• Reduction of carbon dioxide
emissions by substitution of fossil
resources

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 The whole Jenbacher biogas fleet:
•Sewage gas: more than 600 installed engines (470 MW)
•Biogas: more than 4290 installed engines (3,000 MW)
•Landfill gas: more than 1800 installed engines (1,900 MW)

600
30+ years
500 6.200+ engines
5.400+ MW
400
#units/a

MWel/a
300

200

100

0
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
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Biomass Digestion Siggerwiesen

Gerhard Klammer
DDA - Biogas-Workshop - 11/21/2006
GE Energy Jenbacher products

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Biomass Digestion Siggerwiesen

Gerhard Klammer
DDA - Biogas-Workshop - 11/21/2006
GE Energy Jenbacher products

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Model solution for ecological and
economical energy generation

The biogas plant in Soltau, Germany, uses corn and rye as biomass to power three of
GE's Jenbacher J420 cogeneration systems. The facility generates 4.2 MW of
electricity, which is fed into the regional grid. In addition, the Jenbacher engines
produce 4.3 MW of thermal energy, which is used to support an integrated yeast-
production process.
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Palm oil … promising electricity supplier for
the future

The palm oil production process generates huge quantities of organic

waste material that, if not processed, has a negative impact on the
ecological balance. In Thailand, two type 3 of GE’s Jenbacher gas
engines are supplying 33,000 Thai households with a reliable electrical
output of 2.1 MW.

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Cow power: biogas from 2,500 tons of
waste daily powers 1 MW plant

In India, a J320 Jenbacher biogas engine of GE is powering a

successful demonstration cattle manure-methane cogeneration
plant at a large dairy complex, helping to address the region’s
mounting energy and environmental needs.

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Gas engine supporting farm operation
In Pig City, Philippines, one of GE’s Waukesha APG 1000 Enginator®
running on digester gas produces 1,117 kW of electricity, which is used for
farm operation. Excess electrical output is sold to the local grid, and the
heat produced is used for the farm’s incubators. This site was named one
of the “World’s Best Power Plants” in the January-February 2010 issue of
Diesel and Gas Turbine Worldwide.

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China’s first chicken manure-biogas plant

Two type 3 of GE’s Jenbacher biogas engines generate an output of 2 MW

while helping to solve the farm’s waste problems. The farm north of
Beijing, China, owns three million chickens, producing 220 tons of manure
and 170 tons of wastewater each day.

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GE Jenbacher - Reliable operation on
biogas
Biogas Gosdorf/AT
Achieved 8,740 out of 8,760 oph/y in 2005
99.8% Availability with Biogas
Average >98% fleet reliability at Biogas (1,000+ units)

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Optimized plant concepts for biogas
installations
Gas Requirements
• Gas pressure
• Methane number
• Gas temperature/relative Humidity
• Heating value fluctuation
• Contamination
• Sulphur
• Ammonia
• Halogens
• Silica …

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Gas Requirements:
• Gas temperature < 40°C
 mixture temperature 
 limited by rubber materials of gas train 

•Relative humidity < 80%

(at every gas temperature)
 condensate in gas supply 
–filter; pressure regulator; gas train,.....
–condensate in engine/intercooler 

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Gas Requirements
Sulfur:
H2S < 700 mg/100% CH4
 Standard maintenance schedule

 H2S < 2000 mg/100% CH4

 „modified“ maintenance schedule

acidification of oil 
reduced Oil lubricity 
SOx + H2O  corrosion 
deposits in exhaust gas heat exchanger, when temperature is
below dew point 
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 Reduce humidity
Gas pipe + pre heating  second best solution Active humidity reduction  best solution

Cooling system

biogas
soil Gas compressor Gas compressor

Condensate trap Condensate trap

• Only reduction of rel humidity; works

only at a low gas temperature level
• Water content is not changed
• Avoid condensate drain off in
subsequent parts
• Gas cooling by gas pipe in soil helpful,
but no controlled condensate removal
• Effective reduction of water
content
• Reduce danger of having
condensate in the gas system
• Reduce risk of corrosion!

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Gas humidity / cooling:

• Gas filter filled with condensate • Amounts of condensate water

water are significant
• Distance to dew-point to small • Taking measures upfront is
important
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Optimum Layout of gas supply

Condensate trap at the

lowest point
Condensate drain
below blower level

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Gas Requirements TI 1000 – 0300
Sewage Treatment Plant
Sulfate deposits
exhaust gas temperature
below dew point

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Dew-point-line for SOx
170

150
Acid dew-point [°C]

130

110

90
Cooling of exhaust gas not below 220°C (180°C) recommended!
70
≈ 100 ppm H2S in Fuel gas
(LHV = 6,5 kWh/Nm³)
50

0 10 20 30 40 50
Acid concentration in exhaust gas [mg SOX/m³]

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Solution  special Biogas heat exchanger

• Cooling down to 180°C or 220°C

• Exhaust gas heat exchanger without pipes at the bottom  no condensate
around the pipes
• Big condensate trap (DN50) + falling condensate pipes

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Oil Requirements

Biogas plant DK
Polymerization of oil

H2S approx. 3400 mg/100% CH4

oil change interval
exceeded by 100%

Sulfur

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Fuel Gas Quality / Engine Operation
Sulfur content

Concerns for gas engine operation

• Lubricating oil becomes acidic and loses its

lubrication capability:
o Oil must be changed more frequently
o Moving parts of the engine become
o Excessively worn 
• At very high H2S content (2,000-4,000 ppm)
some engine components suffer direct
damage 
• Acid attacks and corrosion on metal parts in
conjunction with condensate H2S + H2O 
• Deposits in the exhaust gas heat exchanger Σ H2S < 700 mg/10 kWh without
if the temperature drops below the acid dew oxidation catalyst:
point  -> standard maintenance plan

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Desulfurization Technologies
Technology Overview

Separation Absorption
Biological process Adsorption
process physical / chemical
Separation H2S is utilized by Adsorption on surface of Physical solving of gaseous media
principle microorganism as a substrate solids in liquid scrubbing media
Microorganism require specific additional chemical /catalytic + chemical reaction in liquid phase
operating condition (T, conversion to H2SO4 resulting in higher efficiency
nutrients) resulting in higher loading

Design / plant Internal: in fermenter activated carbon filter Physical scrubbers

external: trickling biofilter, Bio zinc oxide Amine scrubbers
scrubber Fe-carrier
Typical Stable gas conditions Fine desulfurization Industrial scale application
application coarse desulfurizaiton < 5 to 10 ppm < 5 to 10 ppm
< 50 to 100ppm
Operating nutrient supply, oxygen air injection, high pressure and low
requirements demand, water, ambient specific Fuel gas condition (T, temperatures
conditions rH) regeneration of media requires
heat energy
Suppliers S+H, Bio-Gasclean, Thöni, Siloxa, Selecta Malmberg, Lurgi, Flowtech,
Entec, BASF, SüdChemie GTP
Paques Muche, Sulfa Treat DGE, Cirmac

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Desulfurization Technologies
Technology Overview

H2S content in raw gas:

Typical H2S content
Application Remark
in raw gas
Natural Gas 0 to 10 ppm Sulfur in odoration
Biogas
- Nawaro w/ desulfurization 0 to 50 ppm Sulfur from decomposition of organic
- Nawaro w/o desulfurization 100 to 200 ppm mater (proteins),
- waste utilization 1.000 to 2.000 ppm Concentration in raw gas
- pulp & paper industry up to 30.000 ppm Dependent on substrate
Sewage Gas 200 ppm
Landfill Gas 100 ppm
Wood Gas 50 to 100 ppm Field crop higher – fertilizer
Steel Gas
- BFG low Dulfur in coal / coke
- Coke Gas low after gas treatment Gas treatment by customer
- BOF, FOF low Pig iron is desulfurized prior to steel
plant

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Desulfurization Technologies
Technology Overview

The following parameters must be considered when selecting a suitable desulphurisation

technology: Gaszusammensetzung CH4, CO2, H2S einer Biogasanlage (Entsorger)
80.0 1600.0

• H2S content in the raw gas 70.0 1400.0

• Target H2S in clean gas 60.0 1200.0

• Fluctuations in the raw gas

CH4, CO2 [vol.-%]

50.0 1000.0
quality and quantity

H2S [ppm]
40.0 800.0
• Requirements on reliability
and availability 30.0 600.0

• Maintenance measures 20.0 400.0

operational management CH4 [vol%]
CO2 [vol%]

• Investment costs, operating 10.0 H2S [ppm] 200.0

costs. 0.0 0.0

02/06/04 06/06/04 10/06/04 14/06/04 18/06/04

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H2S reduction
Air dosing Biological H2S reduction
Biogas biogas

air
air water

• Allocation of air is important • Saturate the water content of the gas

• Consider max. air volume • The additional air increase corrosion
• H2S reduction is not constant activity
• The additional air increase corrosion • H2S reduction is stable
activity • Higher investment costs

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Desulfurization Technologies
Sulphide precipitation

Application: Biogas coarse cleaning

Rohgas CAPEX Low, only dosing pump

OPEX Dosing of FeCl2 or FeSO4

depending on sulfur in feed
comparatively high

P-41 H2S Depending on salt input

Separation < 10 ppm reachable
Eisensalze
Fermenter

Substrat Gülle
Control Dosing of Fe-salts

Characteristics
• Prevents H2S generation in gas phase by precipitating sulfur to iron salts in liquid phase
• No injection of air – no degradation of fuel quality
• Slow adjustment on changing operating conditions (H2S content)

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Desulfurization Technologies
Biological Desulphurization

Application: Biogas coarse cleaning

Rohgas CAPEX Low, air injection and

adaption of fermenter
OPEX Low, heating and air
Luft
Besiedelungsfläche
injection
H2S Coarse ~ 50% efficiency
Separation < 50 to 100 ppm
Fermenter
Control Air injection, O2 level in
Substrat Gülle fuel gas to be monitored

Biological desulfurization Characteristics

1. Absorption of H2S to liquid phase
2. Conversion by microorganism
(Thiobacillus) to elemental sulfur
3. Oxidation to sulfate and discharge
• Additional surfaces in fermenter for
microorganism necessary
• injection of air leads to degradation of fuel
quality
• slow adjustment on changing operating
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Desulfurization Technologies
Biological Desulphurization – Trickling Biofilter

Application: Biogas coarse cleaning

Clean gas

Characteristics Scrubbing
media

• External reactor for bio trickling

microorganism heating
cooling
filter

population – better
control of Air
desulfurization
process Raw gas nutrient CAPEX High, large volumes for
• Increase of water
solution
reactor required
content and inert gas water
OPEX Low, air + nutrients,
in fuel gas heating / cooling
waste

• Slow adjustment on water

H2S Coarse
changing operating Separation < 50 to 100 ppm
conditions (H2S Control Air injection, nutrients and
content) Trickling biofilter pH-value, O2 content in
fuel gas
Bruck a.d. Leitha
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Desulfurization Technologies
Biological Desulphurization – Bio Scrubber
Application: CAPEX High, significant plant
Very high H2S content complexity (3 reactors)
Clean gas
waste
gas OPEX medium, air + nutrients,
Scrubbing
media
also NaOH, heating
H2S Coarse/Fine
heating
bio scrubber Separation < 20 to 50 ppm
cooling NaOH

Control Air injection, pH-value by

nutrient
solution
water
NaOH dosing

bio
Raw gas reactor
settler

Bioscrubber Paques
Air

Characteristics:
Papierfabrik Hallein
• NaOH scrubbing and external J C773
regeneration in bio reactor sulphur
1x JMS 320 GS
• No degradation of fuel quality
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Gas blending and switching

• Allows gas blending/switching during full load

operation
• Any gas blending ratio between 5 and 100%
can be chosen
• Operation stays continuously controlled by
LEANOX®

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