State of the art of biogas technology - Examples from Germany
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Energy
State of the art of biogas technology - Examples from GermanyOctober 2010, Jyväskylä, Finland
www.german-renewable-energy.com
Jens Giersdorf, German Biomass Research Centre (DBFZ)
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Content
German Biomass Research Centre (DBFZ) Biogas development in Germany Biogas technologies Economics of biogas production in Germany Recent trends and challenges
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Energy
German Biomass Research Centre (DBFZ)
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German Biomass Research Centre (DBFZ)
DBFZ founded in 2008 as a non-profit company owned by the German Federal Ministry of Food, Agriculture and Consumer Protection (BMELV)
2009: 134 employees, 149 projects Application oriented technical, economic and
environmental R&D activities Consultancies for private/public institutions Policy assessment for federal ministries Feasibility studies for bioenergy plants
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Energy
Biogas development in Germany
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Number of biogas plants and installed electricity power
Source: DBFZ 2010
0
1000
2000
3000
4000
5000
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010*
Anl
agen
zahl
[-]
0
500
1000
1500
2000
2500
Inst
allie
rte
elek
tris
che
Leis
tung
[M
Wel
]
> 500 kWel davon > 1 MWel70 bis 500 kWel davon 70 bis 150 kWel< 70 kWel install. el.Leistung [MWel]
Electrical power generation from biogas (2009): 10.5 TWhel (real), equals 34% of power generation from biomass in total, respectively 1.8 % of German brutto electrical power generation
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Share of substrates (% FM) in German biogas plants
6%3%
4%
48% 2%2%
24%
9%
Pig liquid manure
Cattle liquid manure
Cattle solid manure
Other manure
Maize silage
Grass silage
Grains
Whole plants silage grains
Grass
Other energy crops
Water
Manure (37%)
Man
ure
Energy crops (63%)
Ene
rgy
crop
sSource: Biogasmessprogramm II, FNR, 2009
n = 413
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Energy
Biogas technologies
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Scheme of processes in a farm-based biogas plant
Source: Biogas – an introduction, FNR, 2009
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Types of biogas digestors
System Continuous DiscontinuousCategory Continuous stirred-
tank reactor (CSTR) Plug flow digestor Batch/
Percolation
Symbol
Example
Substrate Characteristics
Liquid, 12% total solids
Viscous, up to 40% total solids
Solid, structured, stackable, humidification through sprinkling
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Continuous stirred-tank reactor (CSTR)
Source: Handreichung Biogas, FNR, 2009; DBFZ 2010
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Continuous stirred-tank reactor (CSTR)
Advantages Cost-effective construction > 300 m³ Flexible flow-through/storage operation Maintenance without reactor emptying
Disadvantages Cover sheet for large reactors is complex/expensive Short circuit currents may occur, retention time insecure Scum and sink layers may occur
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Plug-flow digester
Sources: Handreichung Biogas, FNR, 2009; Eisenmann AG 2010
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Plug-flow digester
Advantages Cost-effective construction for small plants Separation of fermentation steps in plug-flow No scum nor sink layers, short retention time Optimal retention time due to prevention of short circuit currents Low heat losses due to compact construction form
Disadvantages Construction only for small plants feasible Maintenance of stirring devices requires complete emptying of
digester
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Batch/percolation
Advantages Utilization of solid substrates Modular construction, flexible adaption to demands, low investment Few material handling equipment, reduced investment and
maintenance costs, low process energy demand
Disadvantages Delayed operation of several modules for continuous production Incomplete mixture: zones with reduced gas production may occur Installation of security equipment required Large quantities of inoculate needed for high biogas yields
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Energy
Economics of biogas production in Germany
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Investment costs
Investment costs depend on…. Technical equipment of the plant Development costs of the property (road, canalization, etc.) Access to energy grid, heat grid, manure storage tank if necessary Substrate for digestion (biogenic waste treatment plants more
expensive than energy crops due to higienisation)
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Investment costs
Source: Bundesmessprogramm II, FNR, 2009
Total investment costs [Mio €]
Rel
ativ
e fr
eque
ncy
Installed electr. capacity [kWel]
Spec
ific
inve
stm
ent c
osts
[€/k
Wel]
Total investment costs: 1 – 1.5 mio USDSpecific investment costs: 3,800 – 5,000 USD/kWel
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Operating costs
Substrate costs Costs for spreading of digestate Maintenance costs Labor costs Process energy demand Costs for consumables Costs for depreciation and interest
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Annual total costs
Depreciation Base rate
Purchase of energy crops
Other direct costs
Labor costs
Maintenance contractsOther operating costs
Rel
ativ
e an
nual
exp
endi
ture
s[%
of t
otal
cos
ts]
Source: Bundesmessprogramm II, FNR, 2009
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Production costs for electrical energy
Source: Bundesmessprogramm II, FNR, 2009
Prod
uctio
n co
sts
for e
lect
rical
ene
rgy
[€/k
Wh e
l]
Electrical utilization ratio [%]
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Revenues
Revenues for electricity: Feed-in-tariff Substitution of expensive own consumption Revenues from direct marketing/sales
Revenues for heat: Constant heat demand, especially in summer Costs for heat conduction Alternative heat costs
Revenues for disposal: Additional costs for treatment Revenues free plant (without additional transport costs) If applicable higher environmental regulations for the plant
Revenues for digestate (substitute for mineral fertilizer)
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Composition of revenues
Electr. Heat sales Digestate Digestate salesHeat savings
Com
posi
tion
of
reve
nues
[€/a
]
Source: Bundesmessprogramm II, FNR, 2009
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Important factors for success
Optimal choice of biogas plant location of major importance
Low substrate costs Year-round demand for heat and electricity
Skilled employees with enthusiasm for the challenge „biogas plant“
Professional plant layout Long-term financing
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Energy
Recent trends and challenges
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Biomethane feed-in plants in Germany
About 38 biogas upgrading and feed-in plants operating (23,520 Nm³/h capacity)
High costs for upgrading of biogas to natural gas quality requires large plants (> 2 MWel)
Gas grid can be used as storage facility Optimization of heat use and/or satisfaction of peak loads
Several feed-in plants planned, but development slowed down
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Biomethane feed-in plants in Germany
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Integration of bioethanol and biogas production
Sources: Agraferm, 2010, Verbio AG, 2010
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Challenges
Optimization (acceleration) of process biology Improvement of heat utilization concepts Optimization of „dry fermentation“ to increase use
of ligno-cellulosic substrates (agricultural residues) Reduction of biomass/methane losses during the
production process Promotion of biomethane application (esp. as
transport fuel)
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Energy
Thank you for your attention!
Deutsches BiomasseForschungsZentrum German Biomass Research CentreTorgauer Straße 11604347 Leipzig, Germany
www.dbfz.deTel./Fax. +49(0)341 – 2434 – 112 / – 133
Contact:Jens [email protected]