Introduction
While our planet warms and the effects of climate change become more prolific and disruptive, the global demand for energy continues to grow. In combination with significant improvements in energy efficiency, new sources of clean and renewable energy must be exploited to support overburdened infrastructure that is supplied by aging conventional power systems.
Quadrogen Power Systems, Inc. of Vancouver, BC, Canada, is committed to the development and delivery of ultra-clean renewable energy systems. Its focus is on biogas fuelled combined heat and power (CHP) systems that offer class-leading efficiency, ultra-low emissions, and improved economics through increased asset utilisation.
Background
While biogas production and the cogeneration of power and heat is commonplace throughout Europe, North America’s abundance of cheap energy has so far limited this concept’s popularity to early-adopters. However, as we become more aware of the need to reduce our greenhouse gas emissions and of practical ways to do so, we can benefit from European experience with distributed generation and methane-emissions reduction. The sooner that innovative North American cogeneration projects demonstrate viable economic and environmental advantages, the earlier and more extensive the uptake will be. This will in turn lead to a more significant impact on greenhouse gas reduction and climate change.
Biogas is produced by the anaerobic (i.e. in the absence of oxygen) digestion of organic material and consists of approximately 60% methane and 40% carbon dioxide. Wastes such as municipal solid waste (MSW) in landfills, sewage sludge at waste water treatment plants (WWTP), and agricultural livestock manure are all materials that are commonly processed using anaerobic digestion.
In landfills the process is consequential since the buried material naturally decomposes in an oxygen-depleted environment, in turn releasing the biogas that either escapes to the atmosphere or is collected by a landfill-gas collection system for flaring or power generation. At WWTPs, the sewage sludge is digested to reduce its volume and its pathogen count, which reduces the associated disposal and disinfection costs of the treated sludge. Some larger agricultural operations also use anaerobic digestion as part of their manure management strategy for similar reasons as municipal WWTPs. Anaerobic digestion also controls odour and improves the nutrient uptake when the digested manure is applied on fields as fertiliser
The Opportunity
Since methane has twenty-one (21) times the global warming potential (GWP) as an equivalent amount of carbon dioxide, its release to the atmosphere should be avoided and by converting it to carbon dioxide its warming effect can be significantly reduced. While flaring biogas is commonplace (to oxidise the methane into carbon dioxide) it does no useful work. If the methane was instead used to substitute fossil fuels it would lead to indirect reductions of greenhouse gas emissions. Additionally, contaminants in the biogas result in air pollution when raw biogas is simply flared. For example, a common biogas constituent is foul-smelling hydrogen sulphide (H2S) which generates acid-rain forming sulphur oxide (SOx) emissions when burnt.
Depending on the feedstock being digested, biogas contaminants vary in type and concentration and pose different challenges for the power equipment being fuelled. Using biogas as a fuel poses various challenges. For example, the above mentioned H2S also combines with water vapour in the combustion process to form sulphuric acid that attacks engine components and rapidly degrades engine oil. Furthermore, these sulphur compounds poison fuel cell catalysts as well as the emissions-control catalysts used with combustion engines.
Siloxane contaminants are usually present in biogas from landfills and WWTPs. These volatile organic compounds (VOCs) oxidize in power equipment, forming microcrystalline silica that is abrasive, causing engines to erode, and is thermally insulating, causing local hot-spots that lead to damaging pre-ignition conditions. Figure 1 below shows combustion engine components that required replacement due to siloxane contaminated fuel.
turbo junbacher
Quadrogen is developing its Integrated Biogas Pre-treatment System (IBPS) to address this issue directly. By efficiently cleaning the biogas of its contaminants the maintenance intervals and lifetime of power equipment can be extended. While this is a simple objective, it has remained a challenging task for system designers in the waste-to-energy sector – so much so that engine manufacturers have instead tried to mitigate the problem of fuel contaminants with costly design changes specific to their biogas engines. Unfortunately these counteractive measures fail to address the source of the problem and cannot account for varying contaminant species and their presence in unpredictable concentrations.
Existing biogas clean-up systems claim to remove the common biogas contaminants such as H2S, siloxanes, and water vapour, but have been found to be costly to operate and maintain or fail to adequately and reliably protect downstream equipment. Some of these incumbent “solutions” have evolved to provide mediocre performance yet still require purpose-built contaminant-tolerant engines and specialty lubricants that inflate project costs. Altogether, these designs have also been found incapable of meeting the stringent fuel quality standards of ultra-clean, high-efficiency fuel cell based power plants.
The Future of Biogas Power Generation Systems
A cleaner, higher-efficiency alternative to biogas combustion in engines is the direct electrochemical reaction of the methane into renewable electricity, heat, and hydrogen using a carbonate fuel cell. This mature technology not only offers the unmatched electrical efficiency of 47% (vs. approximately 36% for combustion engines), but also negligible NOx and SOx emissions since the fuel is consumed without burning it. This electrochemical process is described in Figure 2 below, whereby the methane fuel is not oxidized in air as in combustion engines or with flares, but rather reformed into hydrogen and then reacted to cleanly produce electricity, heat, water and carbon dioxide.
Direct FuelCell process using Anaerobic Digester Gas (ADG, or biogas)
The unique advantage of this Direct FuelCell process is that the carbon dioxide present in the biogas does not cause a performance or efficiency loss as it does with combustion engines, where the CO2 acts as a fuel diluent. Since the Direct FuelCell anode CO2 exhaust is returned to its cathode with the reactant air, the biogas-sourced carbon dioxide becomes an active participant in the electrochemical reaction and enhances the cathode reaction kinetics. It is this salient feature of the technology that sets it apart from other biogas-fuelled energy conversion systems.
FuelCell Energy, Inc., of Danbury Connecticut is the world leader in carbonate fuel cell technology with their Direct FuelCell (DFC) power plants. These systems have accrued over 340 million kW hours of power generation from over fifty installations globally. Shown in Figure 3 is a typical biogas-fuelled DFC installation at a waste water treatment plant.
250 kW Direct FuelCell
Figure 3: 250 kW Direct FuelCell at a waste water treatment plant (digesters in the background).
Quadrogen Power Systems, Inc. enjoys a close working relationship with FuelCell Energy (FCE) whereby it both develops renewable energy projects using DFC power plants, and also engineers fuel processing sub-systems for the DFC technology platform.
Due to their higher-efficiency technology, Quadrogen’s renewable power systems emit fewer greenhouse gas (GHG) emissions per kW-hour of energy generated, and only produce greenhouse-quality CO2 exhaust as a result of their ultra-clean design.
250 kW Direct FuelCell
Figure 4: Quadrogen renewable energy system concept.
Key Technology Developments
Integrated Biogas Pre-treatment System (IBPS)
Quadrogen is developing its IBPS to meet the stringent specifications of its fuel cell customer / project collaborator. Its contaminant removal performance will far exceed that provided by commercially available technologies (ppm contaminant levels vs. IBPS’ ppb levels), and features efficient system designs intended to reduce operating and maintenance costs. Quadrogen is leveraging its extensive experience in fuel processing and systems integration to design an efficient and robust solution for any biogas supply.
IBPS-conditioned biogas with lower contaminant levels provides significant opportunity for improved reliability and maintenance costs for any type of power generating equipment. A cleaner fuel supply allows for longer maintenance intervals, higher thermal efficiency, and reduced emissions. Additionally, a robust and effective pre-treatment system will further increase the popular deployment of biogas power generating plants.
H2 Booster
Quadrogen has also developed its H2 Booster system to process the anode exhaust gases of a high temperature fuel cell into a conditioned, hydrogen-rich gas suitable for hydrogen recovery. This H2 Booster technology has been designed to meet aggressive cost and performance targets for the economical separation, and hence co-production of hydrogen from the fuel cell CHP unit. This high-value green hydrogen is produced on-demand for commercial sale and has many industrial uses. It can also be used for zero-emissions peak-power generation, and in the long term, for vehicle refuelling.
Quadrogen’s H2 Booster technology includes specific features that differentiate it from conventional industrial gas processing systems. The reactor vessels incorporate integrated heat exchangers for maximum heat recovery and overall system efficiency and were engineered without moving parts for simplicity in control and extended lifetime durability. They are fabricated by one of Canada’s leading automotive parts manufacturers to leverage that industry’s low-cost manufacturing know-how. Quadrogen’s H2 Booster technology increases the fuel cell asset utilisation and makes efficient and economical on-demand hydrogen separation possible.
A conceptual diagram of a Quadrogen renewable co-production system based on a Direct FuelCell is shown above in Figure 4. It describes the high-level process whereby renewable organic wastes are cleanly converted into valuable energy and fertilizer products.
Carbon Offset Potential
The renewable electricity, heat, and hydrogen generated have no directly-associated GHG emissions since the biogas fuel is derived from organic wastes and is part of the natural carbon cycle of these wastes. Instead of flaring the biogas produced by digesters or landfills, its energy is harnessed to directly offset the use of conventional fossil fuels and their associated emissions. This combination of GHG reduction (from eliminated methane emissions) and carbon-offsetting qualities have earned Quadrogen’s innovative renewable energy projects the interest and funding of prominent firms in the growing carbon trading industry for carbon-credit sales.
Distributed Generation
While Quadrogen’s ultra-clean and renewable energy solutions bring more baseload and peak-power capacity to firm-up the electrical grid, they are also typically close-coupled to the loads they serve. This distributed generation approach not only makes the grid more resilient to systemic faults, but also avoids the inefficiencies (and associated GHG emissions) of the conventional distribution network with its centralised generation architecture.
When hydrogen co-production is included with a DFC-based power plant, the hydrogen fuel can be stored and used on-demand for zero-emissions load levelling. Quadrogen’s biogas fuelled power plants can also store its ultra-clean biogas themselves to provide additional on-demand, low-emissions generating capacity with reciprocating engine generator sets. This capability is of significant value to both the energy networks of today and to the Smart Grids of the future.
Since electric utilities invariably rely on fossil fuel combustion engines to supply their peak loads, Quadrogen’s distributed power plants can alleviate the grid’s dependence on the inefficient, dirty, and costly peak-power generators of the utilities. Furthermore, as other renewable energy technologies such as photovoltaic, wind, and alternative-hydro based generation come online, their weather-dependant, and thus time-varying, generating profiles can be buffered by Quadrogen’s flexible and highly-responsive generating capabilities.
Conclusion
In order to adapt to the changing North American energy landscape, with the challenging co-requirements of increased capacity, reduced dependence on imported fossil fuels, and reduced GHG emissions, innovative and renewable generating concepts will be required. Other renewable sources such as solar and wind energy will undoubtedly play a role in building this capacity, but they rely on a grid that is flexible enough to react to their generating profiles. As a society, one measure of our progress is the level of efficiency in which we co-exist with our environment. Waste-to-energy projects can allow us to close the loop on our energy-production-consumption cycle, and can make our electric grid more resilient with a distributed generation approach. They increase our efficiency, and also help reduce additional methane-based GHG emissions from our past consumption (i.e. landfills) and our current production-consumption practices (e.g. from agricultural and WWTP sources).
Quadrogen believes that its flexible renewable energy systems will play an important role in sustaining our energy grids with electricity, heat, and hydrogen co-products, while also enabling more biogas power production to come online by eliminating the risks associated with contaminated fuel. As with any great challenge, great opportunity for innovation and progress exists, and the technologies and systems being developed by Quadrogen will be important components of a successfully restructured energy network.