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GUIDE TO BIOGAS FROM PRODUCTION TO USE biogasportal.info Guide to Biogas From p

GUIDE TO BIOGAS FROM PRODUCTION TO USE biogasportal.info Guide to Biogas From production to use The Project "Technology Cooperation in the Energy Sector" of the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) supports the Federal Ministry for Economic Cooperation and Development (BMZ) to improve framework conditions, technical assistance and approaches for the deployment of renewable energies and energy efficiency in developing and emerging countries. The English version of the "Leitfaden Biogas" was jointly financed by the following GIZ projects: - Technology Cooperation in the Energy Sector - Project Development Programme (PDP) East Africa - ASEAN-Renewable Energy Support Programme - Promotion of Renewable Energy and Energy Efficiency Programme (PREEEP), Uganda - SINO-German Project for Optimization of Biomass Utilization Supported by: Deutsche Gesellschaft für Internationale Zusammenarbeit Dag-Hammarskjöld-Weg 1-5 65760 Eschborn Germany T +49 6196 79-4102 F +49 6196 79-115 E energy@giz.de I www.giz.de Published by the Fachagentur Nachwachsende Rohstoffe e. V. (FNR) with support of the Federal Ministry of Food, Agriculture and Consumer Protection due to a decision of the German Federal Parliament. Projectholder: Fachagentur Nachwachsende Rohstoffe e.V. (FNR) Internet: www.fnr.de On behalf of: Federal Ministry of Food, Agriculture and Consumer Protection (BMELV) Internet: www.bmelv.de Editing support: Deutsches BiomasseForschungsZentrum (DBFZ) Internet: www.dbfz.de Partners: Kuratorium für Technik und Bauwesen in der Landwirtschaft e. V. (KTBL) Internet: www.ktbl.de Johann Heinrich von Thünen-Institut (vTI) Internet: www.vti.bund.de/de/institute/ab/ Rechtsanwaltskanzlei Schnutenhaus & Kollegen Internet: www.schnutenhaus-kollegen.de Publisher: Fachagentur Nachwachsende Rohstoffe e. V. (FNR) Editorial: FNR, Abt. Öffentlichkeitsarbeit Copyright (Cover): Mark Paterson / FNR; Werner Kuhn / LWG; FNR / iStockphoto Layout: www.tangram.de, Rostock 5th, completly revised edition, Gülzow, 2010 All rights reserved. No part of this work may by reproduced, processed, distributed or archived without written permission of the publisher. Responsible for conclusions and results, concepts and recommendation are only the authors, not the publisher. 3 1 Contents Indizes List of figures................................................................................................................................................................... 9 List of tables................................................................................................................................................................... 12 List of contributors ....................................................................................................................................................... 16 1 Purpose of the Guide ................................................................................. 17 M. KALTSCHMITT, F. SCHOLWIN 1.1 Objective ......................................................................................................................................................... 17 1.2 Approach........................................................................................................................................................ 18 1.3 Contents.......................................................................................................................................................... 18 1.4 Target groups................................................................................................................................................. 18 1.5 Definition of scope ........................................................................................................................................ 19 1.5.1 Technology........................................................................................................................................ 19 1.5.2 Substrates .......................................................................................................................................... 19 1.5.3 Currency of data............................................................................................................................... 20 1.5.4 Scope of data..................................................................................................................................... 20 2 Fundamentals of anaerobic digestion ....................................................... 21 J. FRIEHE, P. WEILAND, A. SCHATTAUER 2.1 Generation of biogas..................................................................................................................................... 21 2.2 Environmental conditions in the reactor ................................................................................................... 22 2.2.1 Oxygen............................................................................................................................................... 22 2.2.2 Temperature ..................................................................................................................................... 23 2.2.3 pH value............................................................................................................................................ 24 2.2.4 Nutrient supply................................................................................................................................ 24 2.2.5 Inhibitors ........................................................................................................................................... 25 2.3 Operating parameters................................................................................................................................... 26 2.3.1 Organic loading rate and retention time of the digester............................................................ 26 2.3.2 Productivity, yield and degree of degradation ........................................................................... 27 2.3.3 Mixing................................................................................................................................................ 28 2.3.4 Gas generation potential and methanogenic activity................................................................. 28 2.4 References....................................................................................................................................................... 30 Guide to biogas – from production to use 4 3 Plant technology for biogas recovery ........................................................ 32 J. POSTEL, U. JUNG, EL. FISCHER, F. SCHOLWIN, T. WEIDELE, H. GATTERMANN, A. SCHATTAUER, P. WEILAND 3.1 Features of and distinctions between various procedural variants....................................................... 32 3.1.1 Dry matter content of the substrate for digestion .......................................................................32 3.1.2 Type of feed.......................................................................................................................................33 3.1.3 Number of process phases and process stages............................................................................34 3.2 Process engineering....................................................................................................................................... 34 3.2.1 Substrate management....................................................................................................................35 3.2.2 Biogas recovery.................................................................................................................................51 3.2.3 Storing digested substrate...............................................................................................................66 3.2.4 Storing the recovered biogas ..........................................................................................................69 3.3 Relevant engineering codes ......................................................................................................................... 71 3.4 References....................................................................................................................................................... 72 4 Description of selected substrates ............................................................. 74 J. FRIEHE, P. WEILAND, A. SCHATTAUER 4.1 Substrates from agriculture.......................................................................................................................... 74 4.1.1 Manure...............................................................................................................................................74 4.1.2 Energy crops .....................................................................................................................................75 4.2 Substrates from the agricultural processing industry.............................................................................. 78 4.2.1 Beer production................................................................................................................................78 4.2.2 Alcohol production..........................................................................................................................78 4.2.3 Biodiesel production........................................................................................................................78 4.2.4 Potato processing (starch production) .........................................................................................79 4.2.5 Sugar production..............................................................................................................................79 4.2.6 By-products from fruit processing ................................................................................................80 4.3 Purely plant-based by-products according to EEG.................................................................................. 80 4.4 Material data and gas yields of purely plant-based by-products .......................................................... 80 4.5 Prunings and grass clippings....................................................................................................................... 80 4.6 Landscape management material ............................................................................................................... 81 4.7 References....................................................................................................................................................... 82 4.8 Annex .............................................................................................................................................................. 84 5 Operation of biogas plants........................................................................ 85 J. LIEBETRAU, J. FRIEHE, P. WEILAND, A. SCHREIBER 5.1 Parameters for monitoring the biological process.................................................................................... 85 5.1.1 Biogas production rate ....................................................................................................................86 5.1.2 Gas composition...............................................................................................................................86 5.1.3 Temperature......................................................................................................................................87 5.1.4 Input volume and fill levels............................................................................................................87 5.1.5 Substrate characterisation...............................................................................................................88 5.1.6 Determination of the concentration of organic acids..................................................................88 5.1.7 pH value ............................................................................................................................................90 5.1.8 Concentrations of trace elements...................................................................................................90 5.1.9 Nitrogen, ammonium, ammonia ...................................................................................................90 5.1.10 Floating sludge layers......................................................................................................................92 5.1.11 Foaming.............................................................................................................................................92 5.1.12 Process evaluation............................................................................................................................93 Contents 5 5.2 Plant monitoring and automation .............................................................................................................. 93 5.2.1 Bus system......................................................................................................................................... 94 5.2.2 Configuration planning .................................................................................................................. 95 5.2.3 Applications/visualisation.............................................................................................................. 95 5.2.4 Data acquisition................................................................................................................................ 95 5.2.5 Feedback process control................................................................................................................ 96 5.3 Process control in start-up and standard operation................................................................................. 98 5.3.1 Standard operation .......................................................................................................................... 98 5.3.2 Start-up process................................................................................................................................ 99 5.4 Disturbance management .......................................................................................................................... 103 5.4.1 Causes of process disturbances.................................................................................................... 103 5.4.2 Handling process disturbances.................................................................................................... 104 5.4.3 Handling technical faults and problems .................................................................................... 106 5.5 Operational reliability................................................................................................................................. 106 5.5.1 Occupational safety and plant safety.......................................................................................... 106 5.5.2 Environmental protection............................................................................................................. 109 5.6 Notes on plant optimisation ...................................................................................................................... 110 5.6.1 Technical optimisation .................................................................................................................. 111 5.6.2 Analysing the efficiency of the plant as a whole (utilisation of substrate on the basis of energy flows)........................................................................................................ 111 5.6.3 Economic optimisation.................................................................................................................. 112 5.6.4 Minimisation of environmental impacts .................................................................................... 112 5.7 References..................................................................................................................................................... 113 6 Gas processing and options for utilisation.............................................. 115 M. WEITHÄUSER, F. SCHOLWIN, ER. FISCHER, J. GROPE, T. WEIDELE, H. GATTERMANN 6.1 Gas purification and gas processing......................................................................................................... 115 6.1.1 Desulphurisation............................................................................................................................ 115 6.1.2 Drying.............................................................................................................................................. 118 6.1.3 Carbon dioxide removal ............................................................................................................... 120 6.1.4 Oxygen removal............................................................................................................................. 123 6.1.5 Removal of other trace gases........................................................................................................ 123 6.1.6 Upgrading to natural gas quality ................................................................................................ 123 6.2 Utilisation for combined heat and power................................................................................................ 124 6.2.1 Small-scale packaged CHP units with internal combustion engines..................................... 124 6.2.2 Stirling engines............................................................................................................................... 132 6.2.3 Gas microturbines.......................................................................................................................... 132 6.2.4 Fuel cells.......................................................................................................................................... 133 6.2.5 Utilisation of waste heat in power-led CHP units .................................................................... 134 6.3 Injection of gas into a grid.......................................................................................................................... 136 6.3.1 Injection into the natural gas grid................................................................................................ 136 6.3.2 Feed-in to micro gas grids ............................................................................................................ 137 6.4 Fuel for motor vehicles............................................................................................................................... 138 6.5 Thermal use of biogas................................................................................................................................. 138 6.6 References..................................................................................................................................................... 138 Guide to biogas – from production to use 6 7 Legal and administrative framework...................................................... 141 H. VON BREDOW 7.1 Promotion of electricity from biomass ..................................................................................................... 141 7.1.1 The bonus system under EEG ......................................................................................................141 7.2 Grid connection and electricity feed-in.................................................................................................... 142 7.2.1 Grid connection ..............................................................................................................................142 7.2.2 Feed-in management .....................................................................................................................143 7.2.3 Power feed-in and direct selling ..................................................................................................144 7.3 EEG tariffs..................................................................................................................................................... 144 7.3.1 Basis for determining payments ..................................................................................................144 7.3.2 Definitions of plant and commissioning date – correctly determining the level of payment ......................................................................................................................................146 7.3.3 Level of tariff payments in detail.................................................................................................148 7.4 Gas processing and feed-in........................................................................................................................ 154 7.4.1 Requirements for payment of EEG tariff....................................................................................154 7.4.2 Transport from the feed-in point to the CHP unit ....................................................................154 7.4.3 Legal framework for grid connection and grid use ..................................................................155 7.5 Heat recovery and supply.......................................................................................................................... 156 7.5.1 Legal framework ............................................................................................................................156 7.5.2 Supply of heat.................................................................................................................................157 7.5.3 Heat networks.................................................................................................................................157 7.6 Recommended further reading ................................................................................................................. 157 7.7 List of sources............................................................................................................................................... 157 8 Economics................................................................................................. 159 S. HARTMANN, B. WIRTH, A. NIEBAUM, H. DÖHLER, U. KEYMER, G. REINHOLD 8.1 Description of model plants – assumptions and key parameters ........................................................ 159 8.1.1 Plant capacity..................................................................................................................................159 8.1.2 Substrates ........................................................................................................................................159 8.1.3 Biological and technical design....................................................................................................161 8.1.4 Technical and process-related parameters .................................................................................163 8.1.5 Capital costs of functional units of model plants......................................................................165 8.2 Profitability of the model plants................................................................................................................ 166 8.2.1 Revenues..........................................................................................................................................166 8.2.2 Costs.................................................................................................................................................167 8.2.3 Cost/revenue analysis....................................................................................................................167 8.3 Sensitivity analysis...................................................................................................................................... 170 8.4 Profitability of selected heat utilisation pathways ................................................................................. 172 8.4.1 Utilisation of heat for drying........................................................................................................172 8.4.2 Heat utilisation for greenhouse heating .....................................................................................175 8.4.3 Heat utilisation for municipal local heating scheme ................................................................175 8.5 Qualitative classification of various heat utilisation pathways............................................................ 177 8.6 References..................................................................................................................................................... 178 Contents 7 9 Farm business organisation..................................................................... 179 G. REINHOLD, S. HARTMANN, A. NIEBAUM, R. STEPHANY, P. JÄGER, M. SCHWAB 9.1 Farm restructuring – future prospects and approaches to optimisation ............................................ 181 9.1.1 Selection of an appropriate plant site.......................................................................................... 181 9.1.2 Impact of biogas plant on crop rotation ..................................................................................... 181 9.1.3 Requirements in terms of land and labour ................................................................................ 182 9.1.4 Time as a factor in technology ..................................................................................................... 188 9.2 References..................................................................................................................................................... 189 10 Quality and utilisation of digestate ......................................................... 190 H. DÖHLER, S. WULF, S. GREBE, U. ROTH, S. KLAGES, T. AMON 10.1 Properties of digestate ................................................................................................................................ 190 10.1.1 Properties, nutrients and value-giving substances................................................................... 190 10.1.2 Contaminants ................................................................................................................................. 191 10.1.3 Hygienic properties ....................................................................................................................... 191 10.2 Storage of digestate..................................................................................................................................... 193 10.2.1 Emissions of ammonia .................................................................................................................. 193 10.2.2 Climate-relevant emissions .......................................................................................................... 193 10.3 Utilisation of digestate on agricultural land ........................................................................................... 196 10.3.1 Availability and nutrient effect of nitrogen ............................................................................... 196 10.3.2 Measures to reduce ammonia losses after field spreading of digestates............................... 197 10.4 Treatment of digestates .............................................................................................................................. 198 10.4.1 Treatment techniques.................................................................................................................... 199 10.4.2 Utilisation of treated digestates ................................................................................................... 202 10.4.3 Comparison of digestate treatment processes........................................................................... 202 10.5 References..................................................................................................................................................... 203 11 Project realisation .................................................................................... 205 ER. FISCHER, F. SCHOLWIN, A. NIEBAUM, A. SCHATTAUER 11.1 Concept formulation and project outline ................................................................................................ 205 11.2 Feasibility study .......................................................................................................................................... 206 11.2.1 Substrate availability ..................................................................................................................... 208 11.2.2 Site selection.................................................................................................................................... 208 11.2.3 Material stream logistics ............................................................................................................... 210 11.2.4 Technology selection ..................................................................................................................... 211 11.2.5 Gas utilisation................................................................................................................................. 211 11.2.6 Evaluation and decision-making................................................................................................. 212 11.3 References..................................................................................................................................................... 213 Guide to biogas – from production to use 8 12 Significance of biogas as a renewable energy source uploads/Geographie/ guide-biogas.pdf