By: Giovanni Rumbolo, Peter Monko, Shimolee Nahar, Xiaoqian Ruan

Project Sponsor: Dr. Raj Rajaram

UGL Tech Team 2 Final Presentation

Recap of Project Goals

Identify and select a technology for AD to be installed in Bronzeville locality

Research gas cleaning and electricity generation technologies

Identify the gas and other by-product markets

Food waste

Source: EPA organic waste treatment

Waste Profile of Bronzeville

Bronzeville, which is part of ward 3, waste generation range lies from 5000-15000 tons/day.

Type of organic waste available in abundance – baked goods, expired produce, fats, oils & greases

Major sources of feedstock: Super markets/grocery: Jewel

Osco, 7 Eleven, Restaurants: many in Chinatown, University cafeterias: 4-5 , Food Manufacturers: 10-12

Sources: Chicago waste characterization study, 2010 Interview with Zeropercent founder Google map data

FEEDSTOCK PRE-TREATMENT SYSTEM

Overview

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Feedstock Pretreatment Contaminants in the feedstock reduces biogas generation, creates a low

value digestate and can interrupt the fermentation process causing maintenance problems.

Technologies Available: grinders, tromells with sieves, magnets, mills, pulpers, screw presses.

ContaminantsBiogas revenueTipping fees

Capital costs

M & O costs

Waste hauling

Recommended Pretreatment Plan

1.Manual separation of large non-desirables2.120 mm Trommel with blades inside to deal with large items3.Trommel with 60 mm sieve 4.Magnetic separator5.Manual separation of plastic and other non-organics6.Grinder with 45 mm sieve

ANAEROBIC DIGESTER TYPES

Overview

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Comparing Types of AD Systems

Site Specific need identification: Type of feed stock => amount of pretreatment needed System design optimization: loading rate, operating temperature,

wet/dry Amount of food waste processed and annual gas yield Types and quality of by-products is the system going to generate

and potential markets for the same in and around Chicago

Researched local and international MSW case studies. Compared the models against the site specific needs: Cold winters, small footprint, limited digestate market, small tipping fees

Technology Wetor Dry

Solids LoadingRange

Type of Reactor Temperature Amount of Waste processed

Annually (tons/year)

Retention time(days)

Amount of biogas

generated(Nm3/metric ton of feed)

Pretreatment needed

Eisenmann Dry 20-40% Horizontal dualStage

Mesophilic 12,000 23 146 Yes

DRANCO Dry up to 40% Single Stage, vertical

Thermophilic 120,000 20 133 Yes

KompoGAS Dry 23-28% Horizontal SingleStage

Thermophilic 13,000 14 130 Yes

Valorga Dry 40-45% Vertical, single stage Mesophilic 240,000 21 114 Yes

BTA Wet 8-9% Vertical, single stage Mesophilic 42,500 23 120 Wet Pretreatment

Comparison of Existing Anaerobic Digester Technologies

Apart from the parameters – Key decision criteria is revenue generated from either electricity using CHP system or refined natural gas

CHP SYSTEMMarket Option 1 - Electricity Generation

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On-site CHP system

One potential solution for the biogas byproduct was the use it to power a combined heat & power system on-site.

This solution would help limit the operating cost of Urban Green Loop and would provide the option of selling renewable energy back to the grid and maximize revenues (RECs)

Our research, based on capital and O&M, suggested three CHP options: Steam Turbine Gas Combustion Engine Micro-turbines

Due to limited biogas refinement needed, reduced capital/M&O costs, and extensive case history the gas combustion engine option would be our recommendation.

Combined Heating and Power (CHP) Biogas Utilization System Overview

Source: http://www.epa.gov/chp/basic/

CharacteristicSteam

Turbine

Gas/Combustion

TurbineMicro-turbine

ReciproprocatingIC Engine Fuel Cell

StirlingEngine

Size50 kW to250 MW

500 kW to40 MW

30 kW to250 MW < 5MW < 5MW < 200 kW

Fuels Biogas Biogas Biogas Biogas Biogas Biogas

Fuel Preparation NonePM filter needed

PM filter needed

PM filter needed Yes None

Sensitivity to fuelmoisture N/A Yes Yes Yes Yes No

Electric efficiency 5 to 30% 22 to 36% 22 to 30% 22 to 45% 30 to 63% 5 to 45%

Operating issues

High reliabilityslow start-up

long life,maintenanceinfrastructure

readily available

Highreliability,high-grade

heat available,no cooling required

requires gascompressor

maintenanceinfrastructure

readily available

Fast start-up,requires fuel gas

compressor

Fast start-up,good load-following

must be cooledwhen CHP heat

is not used, maintenance infrastructure

readily available, noisy

Lowdurability,low noise

Low noise

CommercializationStatus

Numerousmodels

available

Numerousmodels

available

Limitedmodels

available

Numerousmodels

available

Limitedmodels

available

Limitedmodels

available

Installed cost

$350 to$750/kW

(w/o boiler)$700 to

$2,000/kW$1,100 to

$2,000/kW$800 to

$1,500/kW$3,000 to

$5,000/kW$1,000 to

$10,000/kW

O&M costs <$0.004/kWh$0.006 to

$0.011/kWh$0.008 to

$0.02/kWh$0.008 to

$0.025/kWh$0.01 to

$0.04/kWh ~$0.01/kWh

Existing Combined Heating and Power Technologies

Source: EPA Catalog of CHP Technologies, 2004

  10 tons/day 20 tons/day 100 tons/day

Steam Turbine

Biogasgeneratedannually

(kWh)

ElectricityGenerated

(kWh) Revenue* ($)

Biogasgeneratedannually

ElectricityGenerated Revenue* ($)

Biogasgeneratedannually

ElectricityGenerated Revenue* ($)

Eisenmann 5,153,143.00 1,545,942.90 83,790.11 10,306,286.00 3,091,885.80 167,580.21 51,531,430.00 15,459,429.00 837,901.05DRANCO 4,694,301.50 1,408,290.45 76,329.34 9,388,603.00 2,816,580.90 152,658.68 46,943,015.00 14,082,904.50 763,293.42KompoGAS 4,588,415.00 1,376,524.50 74,607.63 9,176,830.00 2,753,049.00 149,215.26 45,884,150.00 13,765,245.00 746,076.28Valorga 4,023,687.00 1,207,106.10 65,425.15 8,047,374.00 2,414,212.20 130,850.30 40,236,870.00 12,071,061.00 654,251.51BTA 4,235,460.00 1,270,638.00 68,868.58 8,470,920.00 2,541,276.00 137,737.16 42,354,600.00 12,706,380.00 688,685.80                   

Gas/CombustionEngine                  

Eisenmann 5,153,143.00 1,855,131.48 100,548.13 10,306,286.00 3,710,262.96 201,096.25 51,531,430.00 18,551,314.80 1,005,481.26DRANCO 4,694,301.50 1,689,948.54 91,595.21 9,388,603.00 3,379,897.08 183,190.42 46,943,015.00 16,899,485.40 915,952.11KompoGAS 4,588,415.00 1,651,829.40 89,529.15 9,176,830.00 3,303,658.80 179,058.31 45,884,150.00 16,518,294.00 895,291.53Valorga 4,023,687.00 1,448,527.32 78,510.18 8,047,374.00 2,897,054.64 157,020.36 40,236,870.00 14,485,273.20 785,101.81BTA 4,235,460.00 1,524,765.60 82,642.30 8,470,920.00 3,049,531.20 165,284.59 42,354,600.00 15,247,656.00 826,422.96                   

Microturbine                  Eisenmann 5,153,143.00 1,545,942.90 83,790.11 10,306,286.00 3,091,885.80 167,580.21 51,531,430.00 15,459,429.00 837,901.05DRANCO 4,694,301.50 1,408,290.45 76,329.34 9,388,603.00 2,816,580.90 152,658.68 46,943,015.00 14,082,904.50 763,293.42KompoGAS 4,588,415.00 1,376,524.50 74,607.63 9,176,830.00 2,753,049.00 149,215.26 45,884,150.00 13,765,245.00 746,076.28Valorga 4,023,687.00 1,207,106.10 65,425.15 8,047,374.00 2,414,212.20 130,850.30 40,236,870.00 12,071,061.00 654,251.51BTA 4,235,460.00 1,270,638.00 68,868.58 8,470,920.00 2,541,276.00 137,737.16 42,354,600.00 12,706,380.00 688,685.80

Biogas Revenue Generated

Assumptions:Spot price for natural gas in Chicago May 2014 (EIA) - $4.69/mmbtu or $ 0.0160/kWhElectricity price is based on Integrys Chicago contract - $0.0542/kWh1 mmbtu = 293.1 kWhSource: http://www.eia.gov/naturalgas/weekly/#tabs-prices-2

GAS PURIFICATION SYSTEM

Market Option 2 – Gas Sales

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Biogas Cleaning Technology

Source: American Biogas Council

04/18/23

General Standards for Natural gas

heating units >1,000 Btu per cubic foot of gas

ComponentTypical Analysis

(mole %) Range

(mole %)

Methane 94.9 87-96

Ethane 2.5 1.8-5.1

Propane 0.2 0.1-1.5

Iso-Butane 0.03 0.01-0.3

Normal-butane 0.03 0.01-0.3

Iso-Pentane 0.01 trace-0.14

Normal-Pentane 0.01 trace-0.04

Hexanes plus 0.01 trace-0.06

Nitrogen 1.6 1.3-5.6

Carbon Dioxide 0.7 0.1-1.0

Oxygen 0.02 0.01-0.1

Hydrogen trace trace-0.02

Specific Gravity 0.585 0.57-0.62

Gross Heating Value (MJ/M3), dry basis 37.8 36-40.2

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Costs of Technology

Only feasible at the volume of >20tons/day

Source: BioCNG

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Revenue from compressed gas

10 tons/day 20 tons/day 100 tons/day

Steam Turbine

Biogasgeneratedannually

(kWh)

Compressed Methane

generated(kWh) Revenue* ($)

Biogasgeneratedannually

(kWh)

Compressed Methane

generated (kWh) Revenue* ($)

Biogasgeneratedannually

(kWh)

Compressed Methane

generated (kWh) Revenue* ($)

Eisenmann 5,153,143.00 3,091,885.80 49,470.17 10,306,286.00 6,183,771.60 98,940.35 51,531,430.00 30,918,858.00 494,701.73DRANCO 4,694,301.50 2,816,580.90 45,065.29 9,388,603.00 5,633,161.80 90,130.59 46,943,015.00 28,165,809.00 450,652.94KompoGAS 4,588,415.00 2,753,049.00 44,048.78 9,176,830.00 5,506,098.00 88,097.57 45,884,150.00 27,530,490.00 440,487.84Valorga 4,023,687.00 2,414,212.20 38,627.40 8,047,374.00 4,828,424.40 77,254.79 40,236,870.00 24,142,122.00 386,273.95BTA 4,235,460.00 2,541,276.00 40,660.42 8,470,920.00 5,082,552.00 81,320.83 42,354,600.00 25,412,760.00 406,604.16

AssumptionsCompression Market $ per MMBTU $ per kWh

LNG 50psi Vehicle Fuel 4.69 0.0160

CNG 5,000psiVehicle Fuel/gas grid 4.69 0.01600

EISENMANN AD SYSTEMProposed System

04/18/23

Proposed System: Eisenmann High Solids AD

Source: http://www.eisenmann.us.com/eisenmann-high-solids-ad-system/

Eisenmann High Solids AD System (cont’d)

Benefits of the Eisenmann Biogas Plant•Continuously mixed plug-flow process•Feedstock flexibility for high solids content•High biogas yield and process stability (higher revenue)•Enclosed system prevents emissions of odors•Modular design reduces costs and decreases construction time

System ComponentsHorizontal agitatorHeating elementsControl systemIntegrated safety systemsPressure tight doorsDouble –membrane gas storageScrew-press separators

SOLID AND LIQUID DIGESTATE

Other by-products

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Other Byproducts

Additional research was conducted to assess the types of use for the AD system by-products.

Solid and liquid digestate have a few market outlets that can be explored.

04/18/23

Refine Compressor Distribute

Low pressure Bio gas

Highpressure Bio gas

Market Research

04/18/23

Product- Solid Digestate

Agriculture-This would be the major market. Every year, the sales of corn and soybeans are able to reach $13 billion . The application of compost to soil can benefit the production.

Landscape Industry-The replacement of topsoil of landscape for industrial or residential clients is relatively expensive. The application of compost could improve the quality of existing soil and save cost to owners.

Nursery Industry-Using compost in nursery industry could benefit the housing industry. However, the market depends on the local economic and demand of high-quality houses in Chicago.

Public Agencies-Based on the various purpose, the high-quality compost can be used in the areas where is connected to human and animals while low-quality compost improve the quality of land and landfill cover.

Residential-the market of residential compost is less stable. There are a lot of factor affecting the sales, including local economy, the housing industry, the culture and population.

04/18/23

Product-Liquid digestate

The major downstream markets soil conditioner or fertilizer in gardens urban farms and turf high-quality fertilizer (with further processing)

Nutrition information of digestate made only from food and slaughterhouse waste.

Nitrogen(kg N/M3 )

Phosphate(kgP2O5/M3)

Potash(kgK2/M3)

Digestate (Liquid) 6.0 0.8 1.5PROS: Rich in nitrogen, especially available nitrogen; some digestate has Phosphorous and Potassium; source of organic matter; inexpensive

CONS: Plants may not deliver nutrients beyond certain distance; regulations can be strict regarding application rate and method; restrictions on grazing following application

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Environmental Regulations

Storage All the site or facility used for the composting of food scrap, livestock waste, crop residue, uncont

aminated wood waste, or paper waste, including, but not limited to, corrugated paper or cardboard should meet all of the requirements under Title 35 Sections 807 & 830-832 of Illinois

Administrative Code

Transportation• The facility should be located at

least 1/8 mile from the nearest

residence in Brownsville.

• The site should be close to

feedstock participants in order to

reduce transportation cost

OPPORTUNITIESConclusions

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Conclusions

Type of AD: Eisenmann SystemBiogas use for maximum revenue:

electricity generation using CHP technology

Solid digestate use: mixed as compost amendment

Liquid digestate use: fertilizer

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Further Directions

Identify a suitable site (needs to be 1-2 acres in addition to composting facility)

Request vendor quotes for exact componentsIdentify the exact nature and amount of

feedstockDetail out systems such as transportation,

packaging, bags, compost dryer, control lab etc.

Work with IL state representatives/lobbyists on HB2335, and SB850 to ease permitting

Identify grants and investors to fund the project

QUESTIONS?Thank you!

04/18/23