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An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

Submitted in the partial fulfillment of the subject of Understanding Natural Gas business Submitted to Dr. B. S. Negi Visiting Faculty Department of Oil and Gas UPES Submitted By Name Ambika Aneja Anchal Bisht Bhanu Pratap Singh Pratik Anand Priyanka Keshri Rahul Kothari Subhendu Shivam Bisaria Shobhit Srivastava Tarun Jaiswal Rupal Jouhari

Roll No R020217009 R020217012 R020217023 R020217047 R020217049 R020217053 R020217066 R020217062 R020217088 R020217093

Acknowledgements The success and final outcome of this project required a lot of guidance and assistance from many people and we are extremely privileged to have got this all along the completion of my project. All that we have done is only due to such supervision and assistance and we would not forget to thank them. We respect and thank Mr. B S Negi, for providing me an opportunity to do the project work in UPES Dehradun and giving us all support and guidance which made me complete the project duly. We am extremely thankful to him for providing such a nice support and guidance, although he had busy schedule managing the corporate affairs. We owe deep gratitude to Dr. S. K. Pokhriyal, (Associate Dean, SoB, UPES), who took keen interest on our project work and guided us all along, till the completion of our project work by providing all the necessary information for developing a good system. We would not forget to remember The Department of Oil and Gas for their encouragement and more over for their timely support and guidance till the completion of our project work. We also heartily thank our fellow batch mates for their guidance and suggestions during this project work.

Ambika Aneja Anchal Bisht Bhanu Pratap Singh Pratik Anand Priyanka Keshri Rahul Kothari Tarun Jaiswal Subhendu Shivam Bisaria Shobhit Srivastava Rupal Jouhari

Table of Contents

Topic

Contributed By

Page No

What is Bio-CNG

Pratik Anand/Rupal Jouhari Ambika Aneja Ambika Aneja

1

Bio-CNG for house hold requirements

Ambika Aneja

5

Bio-CNG as Automotive Fuel

Ambika Aneja

5

Types of Bio-Gas Plants Digester Calculation Plant Size Range Storage Liquefied Bio-Methane Compressed Bio-Methane PSA Adsorption Dust Collectors Gas Transfer Compressor System

Bhanu Pratap Singh Pratik Anand Pratik Anand Rahul Kothari Rahul Kothari Rahul Kothari Rahul Kothari Rahul Kothari Rahul Kothari Rahul Kothari

7 14 17 23 23 23 23 24 26 28

Biogas Pipeline Estimation of Bio- Gas production in Dehradun

Shobhit Srivastava Subhendu Shivam Bisaria Anchal Bisht

30 34

Financial Analysis Financial Calculation Sensitivity Analysis Price Sensitivity Analysis Safety Precautions near bio gas plant

Pratik Anand Pratik Anand Priyanka Keshri Priyanka Keshri Anchal Bisht

45 49 53 54 56

Conclusion

Pratik Anand/ Roupal Jouhari Team Effort

60

Bio CNG Composition Bio-CNG Composition after burning

ETRM and Gas Pricing Decision

Gallery

3 4

43

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An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

What is Bio- CNG? Bio-CNG is a sustainable and eco-friendly alternative energy source to fossil fuels. It is generated from residues and waste materials which reduce greenhouse emissions which would otherwise be released if not captured and treated. As a carbon neutral fuel alternative, Bio-CNG can be efficiently stored and transported in CNG cylinders, providing customers with a more costefficient means of gas distribution and in the long-term advance the nation’s bio-economy footprint by reducing imports of coal and gas. Natural Gas is a clean and safe energy source with a variety of commercial applications, including electricity generation, heating, and fuelling transport. Biomethane differs from fossil-derived CNG/LNG as it is emitted from the decomposition of food and animal waste, collected in an anaerobic digester and then injected into the grid. By using (bio)methane to power a gas vehicle the harmful effects of waste gases are significantly reduced, as only carbon dioxide and water remain after combustion. Bio-CNG is a cheaper, cleaner and quieter way to run an HGV fleet than conventional diesel. Vehicles can run solely on gas (dedicated), or on both diesel and gas (dual-fuel). New engines can provide ranges greater than 500km, with very low efficiency loss compared to diesel.Businesses located off major energy infrastructure can save emissions and costs. Instead of using diesel or distillate fuels, CNG is delivered to the facility via CNG trailers, with no disruption or additional ongoing challenges. Just cheaper, cleaner fuel. Bio-CNG, aka Compressed Biomethane, is the holy grail of natural gas fuel. Substantial emissions can be saved at very little extra cost to CNG. We can provide access to 100% biomethane sourced from food waste, independently verified and approved under the Renewable Transport Fuel Obligation. Fleets can report these GHG emissions savings, as can the the UK towards meeting emissions targets. As per MNRE data, the total biogas potential, in terms of electrical Power, is estimated at 1281 MWe. The major industries generating biogas are Distillery, Sugar, and Starch. These three, together, account for 3/4th of the total biogas potential of India. The other major industries are Pulp and paper, Milk processing, Slaughter house, and Poultry. Bio CNG is the purified form of Biogas where all the unwanted gases are removed to produce >95% pure methane gas. Bio CNG is exactly similar to the commercially available natural gas (CV: ~52000 KJ/Kg) in its composition and energy potential. As it is generated from biomass, it is considered a renewable source of energy and thus, attracts all the commercial benefits applicable to other renewable sources of energy. Bio CNG can directly replace every utility of LPG and CNG in India. It has the potential to be the future of renewable fuel because of the abundance of biomass in India. Bio CNG production will also ease the burden of NG/LPG import for India. It is estimated that Bio CNG can replace 2/3rd of India’s NG import which is currently pegged at 429 billion cubic feet.

1

An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

Fuel CNG Bio CNG LPG (Commercial) Petrol Diesel

Calorific Value (KJ/Kg) 52000 52000 46000 48000 44800

Tariff/ Rate/ Cost Rs. 42/Kg Rs. 35*/Kg Rs. 65.7/Kg Rs. 65.5/Ltr Rs. 41.3/Ltr

Cost of Energy (KJ/Rs.) 1238 1485 700 550 900

Bio CNG production is very cost effective making it one of the cheapest fuels in India. Commercial LPG is the costliest fuel and thus, replacement of commercial LPG with Bio CNG makes for a profitable business model. Biogas to Energy projects alternatives Biogas is a mixture of primarily 2 gases with the composition of 55-60% CH4 and remaining CO2 with traces of H2S and moisture. Biogas is a fuel gas with a calorific value of ~ 22,000 KJ/Kg. The biogas projects can be broadly classified into 2 categories: Biogas to Electric Power Biogas to Bio CNG In the power project, biogas is first cleaned of H2S and moisture and is then fed into a power generating unit for conversion to electricity. There is no need to remove CO2, but removal of H2S becomes important due to the corrosive nature of the gas. In the case of Bio CNG production, biogas is cleaned of H2S and CO2 to produce 95% methane gas. The bio CNG produced is then compressed and bottled for transportation to the utility site. Biogas based power generation projects have existed in India for a long time. Most of the biogas generating industries in India are using this gas for power generation only. The concept of Bio CNG is fairly new in India. It has started to gain momentum and it is expected to become a formidable alternative to power generation.

2

An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

Bio CNG Composition Bio CNG is produced due to the breakdown of organic matter in anaerobic conditions that is in absence of oxygen. It is produced by using raw materials like municipal waste, plant material, green waste, manure or food waste. Biogas primarily consists of methane (CH4) and carbon dioxide (CO2) along with methanogen or anaerobic digestion which enables the fermentation of biodegradable materials. The gas may also consist of small amounts of hydrogen sulphide, siloxanes and moisture. The gases like hydrogen, methane and carbon monoxide can be oxidized or combusted with oxygen. As it releases energy, it can be used as a fuel for cooking or any heating purpose. It can also be utilized in a gas engine. Biogas composition varies according to the surrounding anaerobic reactor conditions and the substrate conditions. The conditions of the reactor which can affect the composition of biogas are pH, temperature and substrate concentration. Landfill gas about 50% methane concentrations. Waste treatment technologies which are advanced can produce up to 55 to 75% of methane which can be further increased in case of reactors with free liquids up to 80-90%. Biogas also contains water vapour for which is a function of biogas temperature. In few cases, biogas may contain siloxanes. They may be formed due to the anaerobic decomposition of substances like detergents and soaps. During biogas combustion which contains siloxanes, silicon is released. The table below depicts the typical composition of biogas:

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An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

Bio CNG composition analysis after burning It is observed that the Carbon monoxide concentration in the flue gas increases with a decrease in concentration of methane. The reason for this is the carbon dioxide content in biogas. If there are large amounts of carbon dioxide in the combustion chamber makes difficult to combust the methane. So, there is an increase in carbon monoxide concentration from 29 to 37 ppm in the exhaust gas. The increase in the mole fraction of nitrogen monoxide in the exhaust gas corresponds to the combustion chamber introducing a high amount of air. The carbon dioxide content in flue gas is approximately 18% and is practically constant. In spite of the expansion in the methane, carbon dioxide focuses do not rise. This is because of the way that an expansion in the methane content in the biogas is related to a lower carbon dioxide content in the biogas. The expansion in fumes gas Nitrogen fixation (with an expansion in the methane substance of the biogas) compares to the burning chamber presenting a bigger measure of air required for oxidation of CH4. In real conditions, biogas combustion will be associated with higher concentration of carbon monoxide and nitrogen monoxide as the combustible mixture will not be mixed perfectly and the combustion temperature will be higher.

In the above graph, the first graph depicts the Biogas production from municipal organic waste and the second graph depicts the Influence of CH4 content in the biogas on the mole fraction of CO and NO.

4

An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

The above graph depicts the Influence of CH4 content in the biogas on the mole fraction of CO2, N2 and O2. The O2 content in the exhaust gas is maintained at a constant level of about 1.3 vol%.

Household Requirements of Bio-CNG The production of biogas for domestic use or domestic cooking depends on appropriate digester on a fine scale. In a digester, the waste which is used to produce biogas is mixed with water for the creation of the right environment for the decomposition of biomass by the bacteria. The process occurs in an airtight tank to ensure the absence of oxygen. The biogas is accumulated at the top of the tank and is taken out with the help of a pipe to the user. It is mandatory to remove the slurry out of the tank so that it can be utilized further like for agricultural fertilizer. Digesters to produce biogas come in many forms and sizes which can vary from 1-metre cube for the household unit to around 10-metre cube for a farm plant and around 1000 metre cube for large installations. A small-scale household biogas system comprises of following components:     

Collection space- liquid, raw slurry, semi-solid or solid human, animal or agricultural waste Anaerobic digestor Slurry storage Gas Handling- gas pump, piping, gas meter, condensate drain and pressure regulator End-use device: boiler or cooker

Biogas feasibility as automotive fuel Upgraded biogas can be interchangeable with natural gas. Selected standard requirements for utilization as vehicle fuel are :

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An Analysis of Bio-CNG: Setup, Handling and Financial Analysis



Operational costs associated with converting to RNG vehicle fuel need to be considered: – New Vehicles or Vehicle Conversions – Operational Costs and Digester Heating –Biogas Upgrading Costs – Dispensing Costs and CNG Compression – Utility Costs – Labor



Financial costs, capital costs and development & permitting expenses need to be understood along with incentives and applicable grants



RNG storing costs must be considered due to vehicle fueling cycles.

6

An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

Types of Biogas Plants MNES officially approved the following 7 types of biogas plants: 1. The Floating-Drum Plant with a Cylindrical Digester (KVIC model), 2. The Fixed-Dome Plant with a Brick Reinforced, Moulded Dome (Janata model) 3. The Floating-Drum Plant with a Hemisphere Digester (Pragati Model) 4. The Fixed-Dome Plant with a Hemisphere Digester (Deenbandhu Model) 5. The Floating-Drum Plant made of Angular Steel and Plastic Foil (Ganesh Mode l) 6. The Floating-Drum Plant made of Pre-Fabricated Reinforced Concrete Compound Units 7. The Floating-Drum Plant made of Fibre-Glass Reinforced Polyester. The image below will be showing the diagrammatic classification of types of Biogas Plants: A. Floatingdrum plant B. Fixed-dome plant

C. Fixed-dome plant with separate gas holder D.

Balloon plant

E. Channel-type digester with plastic sheeting and sunshade.

7

An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

Small Scale Biogas Digester 1. Fixed-dome Plants A Fixed Dome Plant usually consists a non-movable gas holder along with a digester. And this non-movable gas holder is located at the top of the digester. The slurry is sent to the compensation tank when the gas production starts and the gas pressure rapidly rises with the difference between the slurry level in the digestion tank to that of the compensation tank and the volume of gas stored also act as an eminent factor. It is relatively cheaper to install a fixed-dome plant. The major benefit is that it has no moving parts and thus the rusting also is never bothering factor as its made up of steel and hence a longer life of the plant can be expected which usually is more than 20 years. It is constructed beneath the surface hence giving advantages in protection from physical damages and reducing the space required for the plant. This also protects the digester from low temperatures during the night, winter season and also from the sunny and high-temperature seasons. As there are no fluctuations in the temperature, it influences the bacteriological processes in the digester.

The basic lookout of a Fixed Dome Plant (Nicarao design) is shown in the figure: From the figure: 1. Mixing tank with an inlet pipe and sand trap. 2. Digester. 3. Compensation and removal tank. 4. Gasholder. 5. Gas pipe. 6. Entry hatch, with gastight seal. 7. Accumulation of thick sludge 8. Outlet pipe. 9. Reference level. 10. Supernatant scum, broken up by varying level The function s of a fixed dome plant are: 1. 2. 3. 4. 5.

Mixing pit Digester Gasholder Displacement pit Gas pipe

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An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

Function – The upper part of the digester consists gas as stored fluid. The slurry is sent to compensation tank when the gas production starts. The more the volume of gas stored the higher will be the gas pressure. Digester – These are usually masonry structures or cement structure or Ferro-cement exists. The digester is usually categorized on the following parameters:  Cost-effectiveness.  Technical Suitability  Transport costs and availability Both the fixed dome plants and floating-drum plants can produce the same amount of gas but utilization of gas in fixed dome plants is less effective because of the fluctuation in gas pressures. Also if a constant gas flow is required, for example for engines the gas pressure regulator is necessary. Gas Holder – The topmost part must be gas-tight. Masonry and concrete are not gas tight and hence it is needed to be painted with a gas-tight layer i.e. Latex or waterproofer. Also in order to avoid cracking, a weak-ring is fixed during construction. This ring structure protects the holder from cracking because of hydrostatic pressure. Advantages: It has less cost involved during the initial phase and also gives a longer lifespan; No rusting and moving parts are involved; the design is compact and hence requires very less space along with the property of good insulation helping in negative fluctuations in temperatures.; the construction of this plants provides local employment. Disadvantages: It demands high technical skills and special sealants in order to construct gastight plant; even after this the gas leakage is quite common; fluctuation in the gas pressure affect

9

An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

the proper utilization and uneven gas flow. It will be expensive and difficult to excavate in bedrock; special biogas technicians are required while construction and maintenance both.

2. Floating Drum Plants A Floating-Drum Plant usually consists of a moving gas-holder along with an underground digester. This gas holder floats over the fermentation slurry or in other option it floats in a water jacket which is usually its own. The gas drum is been used for gas storage in which the gas is moved down or rise depending on the amount of gas stored. A guided frame is used in order to prevent the tilting of the gas drum. The drum cannot get stuck while floating in a water jacket even if the substrate with a high solid content.

Drum – A floating-drum plant mainly consists of a digester which is of a dome or cylindrical share and a floating gas drum. This drum is facilitated by an external or internal guide frame which provided the drum with an upright position and stability. The drum moves according to the consumption and production. Hence the drum rises up when gas is produced and it sinks back or moves down then the gas is consumed. Size – These plants are majorly used to digest human and animal faeces with daily input for the mode of operation. These are mostly used by small and middle-sized farms where digester size varies from 5 to 15 m3. For a large-scale production that is done at institutes or agro-industrial area, the digester size varies from 20 to 100 m3. Water Jacket Floating Drum Plant These are easy to maintain and are highly applicable as they are known for long useful life and has more of an aesthetic appearance because of superior sealing. And the extra cost involved for the Masonry water jacket is somewhat modest. Types of Floating Drum Plants  KVIC model with a cylindrical digester, the oldest and most widespread floating drum biogas plant from India.

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An Analysis of Bio-CNG: Setup, Handling and Financial Analysis

Pragati model with ...