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Conceptual Design of Centralized Biogas Power Plant (Case Study in Bantul, Yogyakarta, Indonesia)
Conceptual Design of Centralized Biogas Power Plant (Case Study in Bantul, Yogyakarta, Indonesia)
Conceptual Design of Centralized Biogas Power Plant (Case Study in Bantul, Yogyakarta, Indonesia)
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ABSTRACT
Since found in 1821, electricity has become one of most important needs to do daily activities. As
the increasing of population and economy activities, electricity demand will grow as well. Indonesia is a
development country which still depend its electricity supply on oil and gas sources. Since these sources
can be diminished in any time, government should more invest on build renewable energy power plant so
that the national energy dependence wouldn‟t be at stake.
This research is designed approaching to Linko Biogas Plants, Denmark. Parameters which are
used to design this plant are feedstock type, hydraulic retention time, and temperature operation of
digester. This plant utilizes gas turbine to generate electricity. To get the optimum electricity production,
gas turbine pressure ratio is varied, starts from 1.5 until 60.0.
Centralized Biogas Power Plant in Bantul will process 25,000 kg of cow manure each day. All of
feedstock will be mixed with water inside buffer tank. Then, digestion of this feedstock-water mixture
takes place inside two stages digester, both are continuous flow type which is operates in mesophilic
temperature (35oC). Total biogas yields from both digesters are 18,270 m3 per day. The raw biogas is
being purified before it enters power generation stage. In power generation stage, gas turbine uses air as
working fluid. The optimum pressure ratio of air compressor is 10.50, whereas, pressure ratio for biogas
compressor is higher by 1.1. Capacity factor of gas turbine is assumed to be 25% so that the electricity
generation of centralized biogas power plant is 2.109 GWh/year.
1 INTRODUCTION
2 METHODOLOGY
All vessels in this plant are designed as cylinder shape. Vessel is made with 10% oversizing
volume for safety reason. Volume for each vessel is determined using Equation 1.
(1)
Height of digester is determined first according to height of Linko Gas digester. So that, Biogas
Plant in Bantul has the same layer as Linko Gas Digester in Denmark. For another vessel, height diameter
ratio (Eq 2) is determined first. Thus the vessel sizing can be determined using Equation 3 – Equation 5.
(2)
(3)
⁄
(4)
⁄ ( ⁄ )
√ ⁄
(5)
Air, along with biogas, will be burned in combustion chamber. Air is assumed to be ideal gas, so
that
̅ (6)
Compressor and turbine are work isentropically with specific pressure ratio. Pressure ratio defined
as the comparison of fluid out from compressor/turbines with the inlet fluid to compressor/turbines,
according to the following equations:
(7)
(8)
: pressure ratio for compressor
: pressure ratio for turbine
The energy which is used by compressor is defined according to equation below:
(9)
where
: ideal work of compressor
: Specific heat of working fluid (kJ/kmol.K)
M : molecular weight of working fluid (kg/kmol)
The temperature and pressure inside the compressor and turbine is correlated according to the
following equations:
⁄
( ) (10)
⁄
⁄
( ) (11)
⁄
( ) (12)
⁄
( ) (13)
⁄
( )
T1 : temperature of inlet gas of compressor
T2‟ : the ideal temperature of gas leaving compressor to regenerator
T4 : temperature of gas leaving combustion chamber to turbine
T5‟ : the ideal temperature of gas leaving the turbine to high pressure regenerator
k : specific heat ratio of the working fluid
The difference between ideal and actual work of compressor and turbine are defined as isentropic
efficiency of compressor and isentropic efficiency of the turbine . The actual temperature of gas
leaving compressor and turbine are:
(14)
(15)
Before entering to gas turbine, the heat of working fluid is added by using heat exchanger or
furnace/combustion chamber. Combustion needs three requirement elements. It is fuel, oxygen and
trigger. The heat which is added to the working fluid is correlated to the specific heat of working fluid,
working fluid molecular weight and the temperature difference before and after combustion. It can be
calculated using this following equation:
(16)
: Ideal heat added to working fluid
: Specific heat of working fluid (kJ/kmol.K)
M : molecular weight of working fluid (kg/kmol)
T3 : temperature of gas leaving low pressure regenerator to furnace
T4 : temperature of gas leaving furnace to turbine
Due to caloric loss inside the furnace, the actual heat that has to be produce in furnace is:
(17)
: actual heat that must be added to the working fluid
: furnace efficiency
Then the exhaust gas from furnace will be expanded inside the turbine. This expansion produces
energy whose amount can be calculated using the equation below:
(18)
Brayton cycle efficiency is defined as:
(19)
: total efficiency of gas turbine (%)
: mechanic efficiency due to friction on turbine shaft (%)
: generator and conversion from mechanic to electricity efficiency (%)
: net turbine energy which is produced by expansion inside turbine (kJ/kg)
Bantul is located at 110o12‟34” – 110o31‟08” longitude and 7o44„04” – 8o00‟27” latitude. The total
area of Bantul is 506.86 km2. Bantul still has a lot of green areas, rice fields and gardens. Therefore,
25.56% people in Bantul work in agriculture sector (Bantul Government, 2013).
In 2011, Bantul has 59,819 livestock which is 20.37% from the total livestock in Yogyakarta
Province (Salbuyun, 2011). From the total livestock that lived in Bantul, 98% of it is population of cow.
The other livestock are dairy cow, buffalo and horse. From 2010 until 2011, this number of livestock had
increased 4.24% and this growth will increase annually.
Total livestock in Bantul potentially will produce 1,707,588.10 kg manure per day. This manure
production will yield 34,420.74 – 66,818.68 m3 of biogas per day. This biogas yield has the same value as
15,833.54 – 30,736.59 kg of Liquid Petroleum Gas (LPG), 17,898.78 – 34,745.94 liters of diesel fuel,
27,536.59 – 53,454.94 liters of gasoline, and 21,340.86 – 41,427.58 liters of kerosene (Salbuyun, 2011).
The Centralized Biogas Power Plant is designed to supply electricity to city of Bantul. To
minimizing loss at power distribution, three areas are chosen to be alternatives location of Centralized
Biogas Power Plant. Feedstock will be collected from area nearby the plant location. Table 1 is shown the
alternative locations for biogas feedstock.
Table 1 Alternative Location of Manure Collecting Mechanism
Alternatives 1 Alternatives 2 Alternatives 3
Number Number Number
Sub-district of cows Sub-district of cows Sub-district of cows
1 Panjangan*) 4574 Bantul*) 2657 Pleret*) 3440
2 Srandakan 3995 Jetis 2255 Bantul 2657
3 Pandak 3716 Imogiri 2495 Jetis 2255
4 Bambanglipuro 4739 Pundong 3295 Imogiri 2495
5 Jetis 2255 Bambanglipuro 4739 Bantul 2657
6 Bantul 2657 Pandak 3716 Kasihan 2985
7 Pundong**) 3295 Panjangan 4574 Piyungan 4347
8 Sanden**) 2913 Banguntapan 1422
9 Pandak**) 3716
TOTAL 25231 26644 25974
*) Sub-district with mark *) is the location of Centralized Biogas Power Plant
Location with mark **) is the farthest sub-district from the plant. Thus manure from this sub-
**) district will be collected to meet the feedstock requirements (25,000 cows)
For alternatives 2 and 3, Biogas Plant will be built in Bantul and Pleret.
4 DESIGN OF BIOGAS PRODUCTION PROCESS AND POWER GENERATION
After collected from all nearby places, feedstock enter buffer tank to get conditioning treatment.
Inside the buffer tank, feedstock is separated from all impurities, like stone, and mixed with water.
Centralized Biogas Power Plant in Bantul will utilize two stage digesters. Both digesters are continuous
flow digesters. Digestate from first stage digester will enter the second stage digester to get more biogas
production. The other purpose of multiple digestions is to minimize the probability of fresh manure being
washed out before producing biogas. Biogas yield from both digesters is cleaned from contamination such
as hydrogen sulphide, carbon dioxide and water vapour. Then biogas ready to process in power
generation stage.
Centralized Biogas Power Plant in Bantul will produce electricity at the same amount in every unit
time. It means that the electricity production does not depend on its hourly demand. The electricity
installation is on-grid type. If the electricity production from Biogas Power Plant doesn‟t meet the
demand, it needs supplementary supply from other sources.
Centralized Biogas Power Plant in Bantul utilizes regenerative gas turbine. This gas turbine uses
exhaust gas which is mixture of air and biogas from combustion chamber as working fluid. The air is
assumed to be gas ideal, so its specific heat stays constant at various temperatures. Besides, the air
volume in 1 atm and 308 K is 25.28 m3/kmol. All process is summarized in Figure 1 and Figure 2.
Figure 3: Left: slow speed agitator; Right: Agitator assembly in digester (Source: Optimum energy
balance thanks to Amaprop submersible mixers. Accessed from http://www.ksb.com/ksb-
uk/Products_and_Services/waste_water/Biogas/630864/biogas_low-speed_amaprop_art.html, 27 July
2013)
26.00
1.50
5.00
8.50
12.00
15.50
19.00
22.50
29.50
33.00
36.50
40.00
43.50
47.00
50.50
54.00
57.50
Figure 5: Total Efficiency of Power Generation
From total power, 462 kW of it is utilized for agitator inside the digester. So the energy that can be
transfer to the grid is 963.42 kW. The temperature of flue gas which leaves the system is 556.84 K.
Capacity factor of gas turbine is assumed to be 25% (R. Kakka Dewayan, et al., 2014) so that the
electricity generation of centralized biogas power plant is 2.109 GWh/year.
5 CONCLUSION
1. Centralized Biogas Power Plant in Bantul is design to use feedstock from 25,000 cattle manure.
The net electricity from Centralized Biogas Power Plant in Bantul is 963.42 kW.
2. Process design of Centralized Biogas Power Plant in Bantul begins with digestion. For 25,000
cow head manure, it takes place in 15 first stage and 10 second stage digesters which both are
continuous flow ones. This process produces 18,270 m3 of biogas daily. This raw biogas is
filtered using carbon active and water scrubbing technology. Then, it is ready to be used in gas
turbine (Brayton Cycle). This plant utilizes regenerative Brayton Cycle.
3. There are 3 alternatives area to build Centralized Biogas Power Plant in Bantul, which are
Panjangan, Bantul and Pleret. Feedstock will be gathered from nearby farm. This plant use
12,000 liter vacuum tanker to transport the feedstock to plant area.
Centralized Biogas Power Plants can raise energy sovereignty in Indonesia. It also enhances
integrated farming in Indonesia. Biogas in general is one of solutions to waste management and energy
scarcity in Indonesia. But to build Centralized Biogas Power Plant still needs more research from all
education background, such as microbiology, chemical engineering, mechanical engineering, economic,
etc.
6 ACKNOWLEDGEMENTS
Lars Ellegard from BWSC Denmark who willing to discuss about process parameter of centralized
biogas power plant and centralized digester sizing.
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