INVESTIGATIONS

3.1Detailed specification of selected equipment

3.1.1 Biogas storage vessel
The vessel design is on the basis that the flowrate of biogas is 217m3/day with volumetric
composition of CH4 56.2 %; CO2 43.7% and H2S 0.1%. All components are in gaseous phase.

Specifications of the biogas storage tank:

 Vessel Shape: Vertical cylindrical shape

 Vessel height: 13.75m
 Vessel diameter: 2.75m
 Design pressure: 7 bar
 Design Temperature: 308.15 K
 Material of construction: Stainless steel

Assumptions

Material of construction of the tank is stainless steel due to its high resistance to corrosion(H2S is
corrosive) and abrasion. also requires less maintenance. [RoT:] The molar and volumetric flowrates
of biogas were calculated using Standard temperature and pressure (STP) conditions. It was
assumed that the biogas feed is entering at standard temperature and pressure (101.325 kPa and
273.15 K). Based off the volume found, the rule of thumb is that the L/D ratio must be between 2-5,
thus we assumed for the L/D ratio to be 5 [Rot:]. Another assumption made is that the operating
pressure of the anaerobic digestor is at 7 kPa.It was also assumed that the safety percentage be
15%.

3.1.2 Compressed gas biomethane storage vessel

The vessel is designed on the basis that 5.44kmol/day of pure (100%) gas biomethane is fed.

Specifications of compressed gas tank:

 vessel height: 8.72m

 vessel diameter: 2.18m
 Capacity: 32.88m3
 Design pressure: 7 bar
 design temperature: 318.15 K
 material of construction: Carbon steel

Assumptions

the residence time was assumed to be 2 days because due to the small production of gas
biomethane, it is most likely that it would be depleted quickly. Operating pressure was determined
to be 5.36 bar but to account for safety the design pressure is 7 bar. Design temperature ..... The L/D
ratio used to find the dimensions of the tank was assumed to be 4:1[RoT:].
3.1.3 Liquefied biomethane storage vessel
Liquid biomethane storage tank was designed on the basis that 5.44kmol/day of pure biomethane
feed.

Specifications of liquified biomethane tank:

 Vessel Shape: Horizontal cylinder

 Vessel height: 6.11m
 Vessel diameter: 2.15 m
 Volume(capacity): 22.2m3
 Design pressure: 7 bar
 Design Temperature: 100.15 K
 Material of construction: Stainless steel

Assumptions

Stainless steel was the chosen material of construction because it has low thermal conductivity, and
it is not brittle at extremely low temperatures [RoT:]. Also, with these advantages it is not
expensive. operating temperature is 110.15 K (-141 C) because bubble point temperature is 111.15K
but design temperature must 10 C below operating temperature for safety. The residence time was
assumed to be a week (7 days) this is to make sure that even if their production is halting the
biomethane fuel vehicles can still functions while production issues are being fixed.

3.1.4 CO2 absorber column

The Column is designed based on dry biogas with flowrate 217m 3/day with the volumetric
composition of CH4 55.8%, CO2 44.1%, and H2S 0.12%. But H2S is removed first before biogas enters
the absorber column. The column operates at 60 oC and 6.5 bar gauge. Biomethane product leaves
with methane purity of 98% mol on a dry basis. Also, no CH 4 leaves with water.

Specifications of the absorber column below (as shown in appendix A):

 Column height: 3.62m

 Column diameter: 0.26m
 Design temperature: 85 oC
 Design pressure: 9.9bar
 material of construction: Carbon steel
 type of packing: pall rings
 packing size & material of construction: 17.17mm and polypropylene
 Volume of packed bed: 0.13m3

Carbon steel was chosen as a material of construction because of its low cost and resistant to
corrosion. Design temperature must be 25C above the operating temperature and design pressure
has to be 3.4 bar above the operating pressure. [RoT:Vessels]. The diameter of the absorber column
was found using a ratio of the diameter of the absorber to the diameter of the packing which is
equal to 15.[RoT:towers]

3.1.5 Biogas compressor

Parameters of the compressor are:

  Type of compressor: reciprocating
 Motor size: 1.49kW
 Drive power: 0.93 kW
 Material of construction: carbon steel

The carbon steel was chosen as material of construction due to its low cost, resistant to corrosion
and abrasion and available in abundance. Calculating the motor size and drive power it was
assumed that compressor and drive efficiencies are 0.85 and 0.90 respectively [RoT: driver]. also,
inlet conditions of biogas were assumed to be 25oC and 1 bar and outlet conditions were 6.5barg
(operating pressure of column) and 204 C [Rot: compressors].

3.2 Process Economics

3.2.1 Economic comparison of process/product options

Table 1: Economic comparison of product options

Raw biogas for cooking Compressed biomethane for Liquefied biomethane
electricity generation for vehicle fuel
& brewing
Capital cost of storage
CEPCI 2004: 444.1 R3 540 000 R1 600 000 R690 000
CEPCI 2023: 800.6
Operating costs - R140266.20  R140266.20 

Revenue R14470.4/day R888/day R6887.5/day

Total Profit R14470.4 -R139378 -R133378.7

Table 1 depicts that producing raw biogas for cooking and brewing proved to be the most
economically feasible on the basis of the total profit when compared to producing biogas for
electricity generation and vehicle fuel. It also has the highest capital cost of the three product
alternatives. Because electricity and vehicle fuel are rather costly, they eventually lose clients,
resulting in decreasing revenue. The capital cost of cooking and brewing is greater due to the high
demand in the food market. Raw biogas is profitable. Thus, all expenses considered, the production
of biogas for cooking and brewing is the most economically prefarable.
3.2.2 Process economics methodology

Capital costs

The capital costs of the storage vessels for each product option were determined using equipment
costs from Coulson & Richardson Chemical Engineering Volume 6, which was multiplied by material
factors and pressure factors [C&R, page 256]. The same procedure was carried out to assess the
capital cost of CO2 removal. To calculate the costs using C&R, the vessels were assumed to fall under
heat exchangers and tanks. CEPCI values used were 2004: 444.1 and 2023:800.6 to account for
inflation of the equipment costs.

Operating costs

for compressors were determined based on their driver power where Coulson and Richardson
Volume 6 was used. The drive power was multiplied with electricity cost to obtain the operating
costs. The assumed electricity cost for 2023 from Eskom was R1.40/kWh.

Revenues of products

of the product options were determined by multiplying the products' energy content with an
electricity price of R1.40/kWh. It was assumed that LHV of LPG was R35.7 per kg, LHV of wood was
R2.75 per kg, LHV of biogas from LPG was R1.45 per MJ, and LHV of biogas from wood was R53.20
per kg.

3.3 Health & Safety issues

There are three categories of health and safety issues relating to the proposed designs:

a.) Raw materials in AD are waste products known to contain pathogenic bacteria. This can be
harmful if incorrectly handled and stored. Exposure without the appropriate personal and
protective equipment and the accidental introduction of these waste products into water
sources can cause diseases including airborne diseases. Additionally, the waste is known to
cause severe odor pollution. CH 4 exits the AD reactor and is highly flammable. Exposure to
ignition sources can result in fires and even explosions due to the high-pressure nature of
the storage vessels.

b.) The leak rate of the liquefied and compressed biomethane storage tank were assumed to be
below 1kg/s. The risk radius for both liquefied and gaseous biomethane was assumed to be
 1 km, respectively. As a result, to ensure safety, the plant should be at least a kilometer
away from households.

c.) H2S can be life threatning if inhaled and causes respiratory and eyesight complications.
Additionally, It is toxic to aquatic life, highly flammable and workers need to be cautious
when dealing with H2S. The recommended technology for H2S removal technology is
biological oxidation (scrubbing) since has a removal efficiency of between 98-99%, less
expensive to maintain, and no additional caltalyst required.

3.4 Environmental issues

SO2 produced by anaerobic digestion pollutes the environment by combining with water and air to
form sulfuric acid, which can cause acid rain. This rain is harmful to nature especially plants because
it can difuse into the ground and dissolve nutrients that plants require to grow. Nutrient deficiency
makes it easier for trees to die, resulting in deforestation and loss of plants that we need for oxygen.
The acid rain also contaminates riverbanks and lakes by lowering the pH of the water, making it
more acidic. A decrease in pH levels may result in the death of aquatic plants and animals.

Carbon footprint generated from using biomethane for electricity is 0.91 kg/kWh and it is
approximately half of the carbon footprint generated from coal-based plant process which is 1.54
kg/kWh. However, this still promotes the greenhouse effect which increases temperatures on the
environments and could eventually lead to global warming and climate change.

The NH4+ concentration in the digestate can negatively impact the environment. If it is at
concentrations higher than 5ppm, it can increase soil toxicity which largely affect the life of
microorganisms in the soil and reduces soil fertility.

3.5 Social considerations

The CBO used two approaches to develop their community. An asset-based approach (which focuses
on recognizing and fixing one's own problems) and a need-based approach (focuses on creating
agencies that deliver services to clients). When the CBO chose the location of the plant, which was a
food market near a transportation hub, an asset-based approach was established. Organic waste
from the food waste be utilized to feed the AD, and the transport hub can be used to carry AD
products. Also, incorporating participants from outside the community to meet their needs expands
on a need-based approach.
If the biogas is used for cooking and brewing it could simply be taken into the market for sales and
this will save expenses as there will not be heavy transportation costs. A total of 179 batches to be
brewed (uMqombothi) per week. Furthermore, heat available per day is 2375873.51 kJ per day and
heat required per vendor is 8368 kJ which means 283 vendors per day can use biogas with sufficient
energy. Hence there will be job opportunities for the community.

Looking at the amount of electricity that can be generated from biomethane, this electricity can be
used by the food sellers as well as the surrounding community. Furthermore, if the biogas is
processed into vehicle fuel, the transport sector would benefit as well. Consequently, all three
product options can benefit the community.

Terms:

CBO – Community Based Organisation

H2S – hydrigen sulphide

AD – Anaerobic digester

SO2 – sulphur dioxide

NH4+ - Ammonium

Km – kilometer

CH4 – methane

LHV – lower heating value

CO2 – carbon dioxide

LPG – Liquefied Petroleum Gas