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12
Urban Waste to Energy from Landfill Biogas Projects and by Pyrolysis Plants
12.1. Introduction
The urban waste is usually dumped in so called municipal land fills or municipal
refuse-dumps. These land fills are usually away from the city and occupy substantial land
areas. Urban waste is transported by road trucks and is dumped into the land fills. Landfill
waste gets fermented by natural bacterial decay (by anaerobic fermentation) and releases
methane rich fuel gas. This gas is called land-fill gas or refuse-tip-gas. Obtaining the methane
rich fuel gas from land-fills is the most economical and environmentally attractive method of
obtaining energy from urban waste. Land-fill Gas is being used as a renewable energy source
in several countries in the world (Table 12.1).
Table 12.1 Landfill Gas Project Sites (1998)
Outlet
Country Boilers/ Kilns Electricity Purification Other Total Trials/
heating furnaces generation/ (pipeline) known schemes scheme
chp* vehicle fuel application planned
United states 7 1 22* 10 14 54 13
West Germany
UK 14+ 5 17 --- 7 43+ 1
Sweden
5 7 7** --- 2 19 6
Italy
Holland 2 --- 4++ --- 1 7 ---
Denmark
Canada --- --- 2 1 3 6 ---
France
Norway 1 --- --- --- 3 4 8
Switzerland
--- --- 3 --- --- 3 ---
Australia
Brazil 1 2 --- --- --- 3 ---
India
Chile 1 --- --- --- --- 1 ---
--- --- ---- ---- 1 1 1
1 --- ---- ---- --- 1 ---
--- --- 1 --- --- 1 1
--- --- --- 1 --- 1 ---
--- --- 1 --- --- 1 1
--- --- --- 1 --- 1 1
Total 33 15 57 13 31 146 32
* one scheme generates electricity and sells gas.
+ includes one research project.
** two schemes generates electricity and also gas for heating.
++ Four schemes are recorded as “ Boiler, CHP”.
Pyrolysis was tried for converting biomass from urban waste to energy. However, the
pyrolysis is used mainly for making wood-charcoal.
12.2. Applications of Landfill Gas
Landfill gas contains predominantly methane (54% by volume). The landfill gas is
used in following applications directly:
--- As a fuel for burning in boilers (without purification)
--- As a fuel for Kilns, Furnaces.
The purified methane obtained from landfill gas is used in following applications
---- As a vehicle fuel.
FROM
During the decomposition, the temperature of the upper portion of the land-fill rises to
about 60°C. Landfill gas is not a pure methane carbon dioxide mix. It has several other gases
including some corrosive gases. For simple burning applications such as furnaces and kilns,
the landfill gas is used without separation of methane and other constituents.
For domestic cooking gas, the landfill gas is converted to compressed Natural GAS
(CNG) or Liquid Natural Gas (LNG) by intermediate process. For use in vehicles as a fuel,
the methane gas is separated form the total landfill gas and is purified to pure methane.
12.4 Landfill Gas Collection System
Landfill sit is usually a void, valley or a former quarry in which the urban waste is
dumped. For example, a landfill site near Bedford, UK is a former brick quarry having
original void volume of 10 million m3 and covering 100 km2 land area. The site receives
about 1000 t of urban waste per day by rail, road from London.
The gas collection system consist of Wells comprising vertical pipes of 80 to 120 mm
diameter with holes in the cylindrical body. The wells are driven in the landfill. The well-
pipes and collection pipes are of polythetene. Knockout drums are installed in the pipelines
for removal of water.
A typical landfill site has 20 to 40 wells and the collection pipe system. The wells are
connected to manifolds and the gas is collected from the manifolds and piping system.
12.4.1. Gas Compression Equipment. The gas if filtered before and after compressor. The
compressor increases the pressure required by the consumer device (e.g. diesel engine or a
furnace).
A single vane type gas compressor may be provided. A typical rating is 690m3/h of
gas at discharge pressure of 1.3 bar. After compression the gas is passed through after cooler,
baffle water separator, fine filter etc, before feeding to the gas consumer device.
12.4.2. Gas Purification. The landfill gas contains methane, carbon dioxide and many other
impurities. Purification of this gas is complex and expensive. The cheaper and effective
methods of purification have been developed recently (1990). These methods employ semi-
permeable membrane and molecular sieves. The purified methane can be used as a fuel for
transport vehicles.
12.4.3. Energy Conversion Equipment. The landfill gas can be purified to pure methane
and then used as a fuel for internal combustion engine. The Internal Combustion Engine can
drive pumping sets. Alternatively, the Internal Combustion Engine can drive generator to
produce electrical energy. For examples, a typical land-fill gas site may have one to four
spark ignition type four stroke internal combustion engines. The engine drives a 350 kVA,
415 V generator. The generator electric power is supplied to the distribution system at 6.6 kV
via a step-up transformer in the substation.
Technically, producing electricity from landfill gas project is more complex and
demanding than use of gas directly as a fuel. Before admitting into the IC Engine, the gas
should be cleaned, filtered and purified.
The plant demands
--- More operational controls.
--- Greater security at outlet of Landfill Gas System.
--- Better operation and management of the total plant.
For producing electricity sufficient gas should be available continuously to operate the plant
throughout the year with a good plant load factor.
12.5. Pyrolysis of Urban Waste to obtain Methane
Pyrolysis is an old process used commonly for making charcoal form wood. This
process can be used for obtaining methane gas (CH4) and other hydrocarbon gases and oil
from wood and urban waste. Solid urban waste is carefully prepared by receiving, storing,
shredding, passing through air classifier, drier, magnetic separators etc. and the combustible
matter is separated form non-combustible metals, glass, etc. For better pyrolysis, the matter is
shredded to small pieces and fed to the pyrolysis reactor.
In the pyrolysis process, the waste biomass is heated to about 500°C to 600°C to obtain
methane (CH4), The gas obtained has various other constituents like CO 2, H2, CO etc.
depending upon the composition of fuel and the temperatures of pyrolysis. (Fig. 13.4). The
main problems in the pyrolysis process are
--- The urban waste has a wide mixture of constituents, high moisture content.
--- Careless dumping of volatile matter and metal sparks during processing leads
to explosions in the pyrolytic reactor.
--- The gas has several constituents, some are corrosive and toxic.
--- The gas has low heat value compared with natural gas.
For urban waste to energy conversion the pyrolysis process has not proved to be successful
due to following difficulties.
1. Danger of explosion.
2. Corrosive gases released by the process,
3. Lesser efficiency due to thermal losses.
4. Low heat value of the gas.
For urban waste to gas conversion, the anaerobic digestion process at low temperature
(60°) without air is most popular. The gas produced is a mixture of methane and carbon
dioxide. This process is simpler, safer and economical. The plan for such process is called
biogas plant.
Pyrolysis Process for Waste Dry Biomass. Several processes have been developed. The
choice of process depends upon the following:
---In feed biomass
---Requirement of end products
---Available technology
---Rating of plant and purpose
---Capital cost allocated
Fig. 12.4 illustrates a schematic of a typical process. The waste dry biomass is
received and stored (1). The Shredder (2) cuts the dry infeed to small pieces (app.2.5 cm dia).
The air classifier moves the lighter dry Shredded biomass pieces with its flow and separates
the heavy non-combustible metal pieces/glass pieces from the fuel. The fuel is dried in drier
(4). The dried fuel is fed into the Pyrolytic Reactor (Gasifier). The pyrolytic reactor converts
the dry infeed to char and fuel gas.
The cyclone (7) separates the Char from the fuel gas plus organic oil. The wet
scrubber (8) separates (1) the organic oil (2) fuel gas and (3) sludge. The gas purifier (9) filter
the gas and delivers it to gas outlet pipe. Residual gas from (9) is reprocessed in the pyrolytic
reactor.
Fig 12.4. Pyrolysis of urban waste
Lecture No: 13
13.1. Wood Gasification (Pyrolysis of wood )
Wood is a source of energy having following composition.
Volalite matter 70 75%
Fixed carbon 25%
Ash 0.5 to 5%
The heat value varies with, type, density and moisture content.
The chemical composition of dry wood is given in Table 13.1
Table 13.1 Chemical Composition of Dry Wood
Carbon C 50%
Hydrogen H 0.6%
Nitrogen N 0.5%
Oxygen O 43%
The organic compounds in wood are cellulose, lignin, sap and some minerals. Natural
fresh wood has 30 to 50% moisture which reduces to about 20% by natural drying. Average
heat value of dry wood is between 19 MJ/kg and 21 MJ/ kg
Wood Gasification is a type of pyrolysis of wood.
The pyrolysis of wood (wood gasification) gives mainly the following, depending
upon the process.
1. charcoal, or
2. charcoal, methane gas, and organic oils
For obtaining charcoal the medium-energy wood gas generated during pyrolysis of
wood is consumed in the process itself.
For obtaining charcoal plus methane gas from wood, the heat is supplied by auxiliary
fuel source and the gas released from the pyrolysis is collected into a separate gas collector.
In the wood gasification process, the main infeed is dry wood. In addition dry
agricultural biomass may also be added.
Organic Matter in Wood + Oxygen + Nitrogen = Wood Gas + Tar, Charcoal, Oils, Acids
Wood gasification is an economical process for cheap wood and wood waste. For
achieving total gasification, it is necessary to circulate air or oxygen or hydrogen. The
processes are named accordingly.
Commercial wood gas producer gives the following byproducts.
Tar ---12%
Acetic Acid and other volatile acids --- 3%
Wood gas ---1.8 to 1.9 Nm3/kg
Crude liquor containing methyle alcohol ---0.5%
The reactor flue gases contain CO which may be burnt along with synthetic gas (H 2 + CO)
obtain from wood waste to provide about 90% heat required in the above process.
The Wood Oil liquid obtained from the above reaction has following compositions:
C = 76.6%
H = 7.05%
N = 0.13%
S = 0.15%
O = 20.05%
Temperature is probably the one parameter which is not readily amenable to management.
(iii) Landfill Gas Systems – Characteristics and Patterns of Use
There are many variations in the pattern of use of extracted landfill gas. These are
generally:
Feed to natural gas main after purification and upgrading;
Feed to local user in an unpurified or relatively unpurified state either for:
a. direct firing to produce heat, or;
b. fuelling internal combustion engines to produce electricity by connection to a
generator and recovery of waste heat.
Figure 14.2 summarises in diagrammatic form the various systems in use or
postulated showing the options available for each process stage.
STAGE METHODOLOGY
I. Boreholes
Ground probe
Vertical /horizontal gas vents
Capped trench systems (permeable material, e.g. rubble)
Buried channel (permeable material )
II. Water removal : cooling/drinking or cyclone separation
CO2 removal : scrubbing, e.g. MEA (monethanolamine), or molecular
sieving (SOLEXOL Process)
Gas processing : upgrading, e.g. adding propane/butane
SO2 removal : iron wool/fillings on impregnated material methanol production
III. Gasometer
Pressure tank
Liquid gas tank
IV. Combustion with/without energy recovery i.e. hot water, hot water/electricity,
electricity via conventional boiler or combination internal combustion engine/heat
exchanger, or gas turbines.
V. Hot water tank
Electric grid system or batteries.
VI. Heating – industrial process, commercial or domestic heating
Mechanical Energy
Electric Motors
Vehicles (liquefied gas )
Typically, systems are kept simple but with considerable emphasis on safety. They
generally comprise a series of 100mm PVC pipes sunk to a depth of 6-10m connected via a
flexible header to 150mm HDPE feeder pipes. The gas is generally drawn from the landfill
using a blower and/or pump and the gases are passed through a cooler, to cool the
compressed gases. Condensate is removed to reduce the moisture content, landfill gas being
generally saturated. The gases then pass through a filter to remove any debris and also any
sulphide content (if the gas is to be used in metal manufacture) by passing through sawdust or
a similar material impregnated with iron oxide.
Safety equipment usually comprises:
oxygen analysers;
low-pressure warning systems;
anti-flashback apparatus/flame arrestors;
ventilators or ventilated buildings;
vandal-proof or buried pipework systems on the landfills;
explosion/flame-proof pumps and electrical equipment.
14.2.2 Energy Production by Landfill Gas Utilisation
Calculation of expected net energy production and overall energy conversion
efficiency from landfills is complex since it needs to consider:
energy involved in landfill disposal operations;
energy content of the refuse input;
gas yield, including production and losses;
the balance of gas supply and demand and need for flaring off excess gas;
efficiency of conversion to useful energy as heat or electricity.
Based on detailed calculations optimal conditions would result in a net energy
production of 1.28 to 1.40 GJ/tonne of refuse deposited and an energy conversion efficiency
of waste to gas of 12 to 22%. Upgrading of the gas to remove acid gases and water vapor
would require additional energy and reduce the overall efficiency by up to one third.
Conversion to useful energy would depend on the equipment used.
The use of a ‘total energy installation’ based on an internal combustion engine with
heat recovery from the exhaust gas, as commonly used, has an efficiency of 90%, reducing
the overall conversion efficiency from refuse to usable energy to 11 to 19%. However, if the
gas is used in a conventional boiler, with efficiency of 50 to 60%, the overall conversion
efficiency would be correspondingly lower.
14.2.3 Constraints on Development of Landfill Gas Utilisation Projects
Major constraints on the development of further gas utilization projects are likely to be:
Size of landfill voids utilized;
Ownership of gas, e.g. gas belongs to site owner, to site lessee, waste disposer or
waste generator?
Availability of potential user or gas-pipeline (for upgraded gas) in close proximity to
the site;
cost of upgrading gas;
feasibility and economic viability of liquefaction following purification;
moisture content and presence of other incombustible contamination in unpurified
gas;
corrosion problems on collection and purification equipment;
site specific factors:
✔ organic content of deposited materials;
✔ C:N ratio of deposited materials;
✔ moisture content and density of deposited materials;
✔ depth of landfill;
✔ permeability of surrounding geology and capping materials to landfill gas;
✔ depth of unsaturated zone within waste materials.
Table 14.1 Landfill Gas Systems