Large Scale Biogas Production in

Liquid Biofuel Industries

WASTE TO ENERGY

Flare,Siam,Krabi Province,Thailand

NathanClarke
PrincipalConsultant WastetoEnergy&
DisciplineConvenor Wastewater
Treatment CPGNZ&Aus

DrChrisHearn
SeniorBiotechnicaland
ProcessEngineer

SimonRuddenklau
Senior
ProcessEngineer&
ProjectManager

JonasHjertquist
ProjectManager

DrJurgenThiele
ResearchDesignManager

CPG Ateamwith35+yearsofexperience

Containerised PilotPlant

Offices/RepresentativeProjectSites Prospects

Anaerobic Digestion
Break down of organic compounds to biogas
Naturally produced in absence of oxygen
Methane (CH4) and Carbon Dioxide (CO2)
Methane High energy potential
Methane considered to be 21 times more
potent than CO2 as greenhouse gas
Capture and destruction of Methane in
optimised processes such as Cigar.

Burning water ?

Methane emission: 50,000 - 100,000 t CO2 equivalent/year

TechnologyComparison

The New Frontier

Keep it simple
Deliver excellent financial performance
Attract Venture Capital funded investment
Reduce commercial risk
Payback period within 20 % of project life
Know your waste and Control your waste

Digester Value Engineering

Covered In Ground Anaerobic Reactor

Substantially improved contact with the waste

High reserve activity (active bacteria ) and capacity
High sludge concentration
High toxicity tolerance
Better growth

IngroundReactorBenefits
Lowerconstructioncost
Lowerloadingrate> robustness
Largesludgeinventory> robustness
Longsolidsresidencetime
Highgasyield increasedelectricitysales
Improvedwastetreatment
Lowmaintenanceandoperationcost
Easyoperation,robustandsimple
CERIncome

Commercial Success
CIGAR Technology Uptake

35
30
25
20

120000

Number of new
plants/year

100000

Total number of
operating CIGAR

80000

total daily waste volume

treated by CIGAR

60000

15

40000

10
20000

5
0
2002

2004

2006

2008

2010

Year of project completion

2012

0
2014

Daily waste volume

treated by CIGAR systems

No of plants in operation

40

Benefits for Biorefineries

Process energy reduction by 80-90 % (molasses ethanol)
Process energy reduction by 50-60 % (dry mill grain ethanol)
> 98 % reduction of methane emissions from biorefinery waste
treatment (palm oil mills, molasses ethanol)
Production of green electricity grid (palm oil mills)
Overall increased biofuel output (10-20 %, palm oil mills)
Reduction of carbon footprint for biorefineries

Khorat,Thailand 2003,CassavaStarchProcessingWaste;
90,000m3 Biogasperday.TotalEnergyproduction~10MW;
USD5MillionROI:18Months

Cigar Manure Indonesia100%SuccessRate

Cigar Kitroonruang,Thailand.ROI24Months
DestroyingMethaneinGenset andFlare,
CH4 21xmoredamagingthanCO2

CER Revenue
Estimate: 100 CER per 1,000 t FFB
Value: USD 5 20 per CER
Additional Revenue Stream BUT
Complex Process
Slow to provide revenue (2 3 years)
Requires additional equipment
Costs associated

Good advice recommended!

CleanDevelopmentMechanism
(CDM)
CDMProject

WasteSource

RegistrationDate

AnnualCERs

Univanich Lamthap*

POME

February2009

43,656

Univanich Siam

POME

Validation

20,895

TBECTha Chang*

POME&Rubber

Validation

54,497

Korat WastetoEnergy

Starch

June2007

310,843

Jiratpattanna

Starch

March2009

24,726

SiamQualityStarch

Starch

April2009

98,372

ChaoKhun Agro

Starch

March2009

48,167

Kitroonruang

Starch

FinalCheck

19,578

TTYCambodia*

Starch

September2008

50,036

Excel

Manure(piggery)

March2009

12,526

Amigo

Manure(piggery)

March2009

5,761

LampungBekri

Manure(cattle)

December2006

18,823

9Projectscertified
byUNFCCC

3Projectsunder
validation

*3GoldStandard
ListedProjects

Duringconstruction

ElectricityGeneration
fromBiogas

SystemComponents
Scrubber
(Vertical)

Scrubber
(Horizontal)

Blowers

Generators

Cigar Design Service

From waste reception through to the gas distribution system,
the complete anaerobic digestion package.

PROCESSOVERVIEW
Sulphide
Scrubbing

Processand
Automation
Control

SludgeEffluentfor
Irrigation
orComposting

Influent

HX

Dehumidification

Covered
InGroundAnaerobic
Reactor

Mix
Tank

Electricity
Generation

LiquidEffluent
to
ExistingPonds

Commissioning
and
OperationSupport

Biofuel/biorefinery related case

studies

Cigar Case Study 1

Palm oil mill

30 ton FFB/h
~ 400 m3/day POME
~ 66 kg/m3 COD
22,000 m3 CIGAR reactor system
System Cost: USD 1.6 million

Cigar Case Study 1

Only ~ 80% biogas use, rest is flared

More than 90% COD removal from POME
CIGAR effluent ~ 3,500 ppm COD
Additional treatments required to achieve
discharge requirements
Final discharge ~ 200 ppm COD

Cigar Case Study 1

> 11,000 m3 biogas per day

952 kW generator installed
Electricity Generated: > 7.1 million kWh/yr
Value in Malaysia: > USD 500,000/annum

Payback Period: ~3 years

Cigar Case Study 2

165,000 Liter/day Fuel Ethanol Plant

from Sugar Cane Molasses
~ 700 m3/day wastewater,180 kg/m3 COD
42,000 m3 in-ground reactor system
CIGAR system Cost: USD 2.3 million

Cigar Case Study 2

Up to 43,000 m3 biogas per day
Used as boiler fuel and flared
H2S content 5,000-10,000 ppm
Replaces heavy fuel oil (19 t/day) for
refinery boiler and steam turbine
At 200 US$/t HFO, 330 d/yr: (2005 prices)

Payback Period: ~2 years

CIGAR the way forward

Agro-industry solid waste digester

~ 1000 t/day feedstock, ~ 350 kg COD /t
Pilot plant tests successfully completed
Up to 100,000 m3 methane per day
Used as gas turbine fuel
H2S content in raw biogas: > 1500 ppm
Project status: feasibility evaluation
Payback Period Estimate: tba

Natural Energy

Experiencecounts
CigarSystemsforThaiBiogasEnergyCompany(TBEC)
Location

Waste

Country

Jiratpattana

Starch

Thailand

Kitroonruang

Starch

Thailand

ChaoKhun Agro

Starch/Fructose

Thailand

Tha Chang

PalmOil(POME)/Rubber

Thailand

3additionalfacilitiesunderway

CigarBiogasSystemsforUnivanich
Location

Waste

Country

Siam

PalmOil(POME)

Thailand

Lamthap

PalmOil(POME)

Thailand

Experiencecounts
Client

Waste

Country

Khorat WastetoEnergy

Starch

Thailand

TAELanna

Vinasse (molassesethanol)

Thailand

SQS

Starch

Thailand

Khorat Starch

Starch

Thailand

Excel

Manure(piggery)

Philippines

Amigo

Manure(piggery)

Philippines

LampungBekri

Manure(beeffeedlot)

Indonesia

TJFarms

Manure(piggery)

Philippines

FILAM(x3)

Manure(piggery)

Philippines

KSBioplus

Starch

Thailand

Ratchasima

Starch

Thailand