Biogas, beyond a mere source of energy.

Enhancing sustainability through accurate biogas upgrading measurements.

In an era where sustainable and renewable energy sources are imperative, biogas stands out as a promising solution. However, maximizing its potential necessitates efficient utilization, achieved through accurate biogas upgrading. These systems play a pivotal role in enhancing the quality and utility of biogas, propelling it beyond a mere source of energy.

Pic: SFP

One notable example is Pentair, a recognised leader in engineering advanced biogas upgrade systems. Pentair's expertise lies in designing and implementing cutting-edge solutions that elevate biogas to a standard comparable with natural gas. With precise engineering and innovative technologies, Pentair empowers biogas to seamlessly integrate with existing infrastructure, unlocking a spectrum of sustainable applications. Pentair has been instrumental in deploying sustainable solutions, including CO₂ recovery plants and biogas upgrading systems.

Biogas upgrading systems play a pivotal role in maximising the potential of biogas as a sustainable and clean energy source. These systems enhance the energy content of biogas by concentrating methane and reducing impurities, enabling it to match the quality of natural gas. This upgraded biogas, often termed biomethane or renewable natural gas, can be seamlessly integrated into existing natural gas grids, providing a direct, clean, and renewable energy supply. It serves as an environmentally friendly fuel, significantly lowering carbon dioxide emissions when utilised for electricity generation, heating, or transportation. Moreover, the ability to store and transport upgraded biogas efficiently enhances its role as a reliable and sustainable energy storage solution.

By transforming organic waste into valuable energy and supporting a circular economy, these systems contribute to waste reduction and the efficient utilisation of biomass resources. “In our pursuit of sustainable progress, we believe in remaining vigilant and thorough, implementing careful controls to minimize revenue losses for our customers while ensuring that our biogas upgrading plants minimise methane slip during purification, making a positive contribution to the energy transition and sustainability goals,” explains Machiel van Essen, NPD Project Manager ─ Technology at Pentair.

Pentair operates a facility called Pentair Haffmans in Venlo, in the Netherlands, where they engineer and manufacture analysis equipment for breweries, CO₂ recovery installations, and biogas upgrading systems. Sustainable Fuel Plant (SFP), an innovative facility dedicated to the production and advancement of sustainable energy solutions, approached Pentair to evaluate the biogas upgrading system that had been installed by Pentair at the SFP site, located in Westdorpe, in the Netherlands. This collaboration extended further through Pentair's partnership with Vaisala, a leading provider of measurement instruments, which played a crucial role in the successful assessment of the biogas upgrading system.

The Challenge.
The assessment of the biogas upgrading system at SFP presented a specific set of challenges that demanded a meticulous approach. Firstly, achieving precise analysis of both the biogas feed flow and the process permeate flow (offgas) was deemed critical due to the complex composition of gases involved. Any inaccuracies in the process had the potential to cause elevated methane (CH₄) levels in the permeate flow, which could significantly impact the revenue of biogas upgrading sites. Operating under challenging wet conditions was an additional hurdle, requiring analysers that could function effectively despite high relative humidity in both the biogas feed and permeate flows. Moreover, compliance with ATEX zones and safety requirements in biogas facilities, had to be ensured. Conducting in-situ analysis was also vital, minimising the need for new analysis lines and providing a more accurate representation of real-time conditions. Lastly, the analysis was intended to be temporary, necessitating easily implementable and removable analysers that could adapt to evolving requirements during the assessment process.

The Solution.

To surmount the array of challenges posed by the biogas upgrading assessment, Pentair joined forces with Vaisala, utilising their extensive experience in the field, to propose a strategic solution for the evaluation. The cutting-edge Vaisala MGP261 and 262 multigas probes were recommended, which proved to be instrumental in addressing the specific requirements of this assessment.

The MGP261 and 262 multigas probes offered a remarkable capability to provide real-time process values, within the defined levels of accuracy and ranges for both CH₄ and CO₂ . A significant advantage was their adaptability to challenging wet conditions, ensuring reliable performance even in high-humidity environments - a crucial factor given the nature of biogas processing. In addition, these probes were simple to install, and comply with the ATEX and safety regulations of biogas facilities.

By synergizing the data obtained from the biogas feed, retentate, and permeate streams, a comprehensive analysis of the entire process was conducted. This holistic approach allowed for a thorough assessment, enabling a deep understanding of the dynamics and efficiency of the biogas upgrading system. The analysis revealed that Pentair's process design conformed rigorously to the specified design criteria. This validation provided strong assurance to SFP that the biogas upgrading system was functioning precisely as intended, in alignment with the set objectives and performance expectations.

The MGP261 and 262 multigas probes delivered accurate and precise measurements throughout the assessment period. Accurate measurement and optimisation of CH₄ and CO₂ levels enhance the efficiency and sustainability of the biogas upgrading process.

“We are committed to sustainable progress, and we always strive to prevent revenue losses for our customers by applying rigorous controls,” Machiel van Essen explains. “Our biogas upgrading plants also reduce methane emissions which we measure with Vaisala MGP261 and 262 multigas instruments to optimise the purification process. This way, we contribute positively to the energy transition and sustainability goals.”

Summary.
In summary, the collaboration between Pentair and Vaisala, leveraging the MGP261 and 262 multigas probes, demonstrated the effectiveness of these instruments in verifying the performance of the biogas upgrading system at the Sustainable Fuel Plant site. The ease of installation and their reliable performance make these probes a valuable extension of Pentair's process analysis kit. This solution has the potential to be offered to Pentair customers in the future, enabling the tracking of both process and material performance, aligning with Pentair's commitment to sustainable and responsible solutions in the field of gases.

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* See also: Monitoring methane and carbon dioxide emissions - Industrial and Environmental. (30/11/2023)

@VaisalaGroup @Pentair @_Enviro_News #PAuto #Energy

Analysers in biogas treatment.

Renewable energy is an area of enormous growth. Global production of biogas from landfills and from biomass is expected to nearly double from 2015-2026. Biogas production is growing at such a high rate as a result of concerns stemming from depleting fossil fuel reserves, incentives from government programs and compliance with environmental laws.

The biogas treatment process begins with the feed of landfill gas from landfills and/or the feed of biomass from organic waste. Biogas feed streams are variable; therefore, process efficiency relies on monitoring the feed stream into the biogas treatment process. In many parts of the world, our trash is sent to landfills and ultimately decomposed in airtight cells underground. The bacteria that digests the waste, releases what is known as  landfill gas, a varying mixture comprised largely of methane and carbon dioxide. Biomass from organic waste, is fed into an anaerobic digester, where biogas is released into the headspace of the digester. The biogas created from the landfill digestion and anaerobic digestion includes varying amounts of H₂S, which is a chemical that must be removed before the gas can be used for energy purposes.

In all biogas production facilities, there is an H₂S removal system, often known as the H₂S scavenger or H₂S scrubber. Monitoring the levels of H₂S at the inlet and outlet of the H₂S scrubber is paramount for evaluating scrubber efficiency and for adhering to environmental regulations. The Applied Analytics OMA series analyzer is ideal for monitoring percent level H₂S at the inlet and ppm level H₂S at the outlet of the H₂S scrubber in biogas production.

@AAInc #PAuto #Environment

Biogas innovation wins.

Vaisala's MGP261 biogas instrument is a winner in the Finnish Quality Innovation competition, where it won the Circular economy and carbon neutrality innovations category. After being recognized as an outstanding example of innovation in the field of sustainable technologies, the instrument now advances to the finals of the global Quality Innovation Award competition.

“This is a great recognition for a product as revolutionary as the MGP261. The Vaisala CARBOCAP® MGP261 Multigas Instrument for Methane, Carbon Dioxide, and Humidity was first introduced in early 2019, with instant benefits for the biogas industry. The Vaisala MGP261 transforms waste into value: The better the entire process is monitored and optimized by reacting to changes in gas composition and humidity, the more efficient the biogas plant becomes. This translates directly into improved profitably for customers and is also good for the planet,” says Vaisala Project Manager Otto Tierto.

The Quality Innovation Award The Quality Innovation Award competition was founded by Laatukeskus Excellence Finland in 2007. It has since grown to become an annual international competition with eight categories. Vaisala’s viewLinc Continuous Monitoring System won the global Quality Innovation Award in 2018 in the Business Innovation category for large companies. In 2021 the international award ceremony will take place in February in Belgrade, Serbia.

A sustainable solution for a greener tomorrow
Lowering greenhouse gas emissions and responding to waste management issues in a time of population growth is challenging. Renewable energy, especially biogas, is a key part of the solution: 

Industrial and municipal waste and wastewater treatment plants, landfills, and even farms can produce electricity and heat from biowaste by using a combined heat and power engine. But running one profitably means improving the quality of the produced biogas; this has been a tough goal to achieve, until now. 

The Vaisala MGP261 is the world’s first in situ three-in-one biogas measurement instrument. It works directly in the biogas stream and is Ex certified up to zone 0.

 “We all need to do everything we can to halt the climate change by transitioning to a circular economy and turning waste into energy,” says Jutta Hakkarainen, Vaisala’s Industrial Measurements business’ Strategy and Business Development Director. “In a resource-efficient business, raw materials are used in an economical and sustainable manner instead of letting them go to waste. Vaisala’s MGP261 multigas instrument helps the biogas production processes become more efficient and improves the biogas quality.” 

@VaisalaGroup @Laatukeskus #PAuto #Finland 

Flow in biogas applications.

Owners, operators and system designers of biogas production and recovery systems will want to explore the innovative ST80 Series thermal flow meter from Fluid Components International (FCI).

These users will find the new Model ST80 flow meter provides optimal performance and the necessary features required for accuracy and repeatability in demanding biogas flow measurement applications. The unit is an easy to install, safe biogas flow meter that delivers a truly best cost
solution.

In anaerobic digester produced biogas, for example, gas flow measurement can be challenged by the dirty, wet nature of this gas. Biogases are also a potentially explosive, mixed composition gas comprised primarily of methane (CH4) and carbon dioxide (CO2), with traces of hydrogen sulfide (H2S) and other gases that require stringent safety approvals to protect people, equipment and plants.

Furthermore, the residuals and particulates in the biogas, along with the H2S component, is a corrosive condensate that deposits itself on the pipe wall and instruments in the pipe, which can clog or foul orifice, vortex shedding, PD, turbine and most other technology sensors. The flow of rates of biogas varies widely too—based on fluctuating plant process demands and seasonal variations in temperature and humidity, requiring low flow sensitivity and wide turndowns.

Thermal mass flow meters using constant power technique, such as the ST80 Series, with their robust, open and cleanable, no-moving parts sensor design provide an ideal biogas application solution in this demanding environment. Furthermore, their international approvals for Div.1/Zone 1, on the entire instrument, ensure safe installation in hazardous biogas processing areas.

The measurement principle of thermal mass flow meters involves heat transfer caused by gas flow. Any moisture or condensate in the gas stream that intermittently contacts the sensors, however, can cause a sudden, momentary change in the heat transfer rate that can result in spiking or fluctuating readings.

Standard thermal flow meters using the constant temperature ∆T (CT) measuring technique are particularly reactive to moisture droplets, while constant power (CP) technique thermal meters, because of their slightly heated sensor that elevates the dew point, are less so.

The ST80 Series flow meter features FCI’s Adaptive Sensor Technology™ (AST™), which is an
innovative, patented hybrid sensor drive. This measuring technique combines, for the first time, both of the industry’s highly proven constant power (CP) and constant temperature (CT) thermal dispersion sensing technologies in the same instrument.

Complementing this new measurement drive technique are a choice of four different flow sensor element designs to further ensure best installed performance, including FCI’s new wet gas solution.

The Wet Gas MASSter™ sensor developed for the ST80 Series optimizes the sensor head design and installation to prevent condensation droplets, or rain, from contacting the sensors.

The ST80 Series flow meters are suitable for pipe diameters from 1 inch to 99 inches [25 mm to 2500 mm] and air/gas temperatures up to 850°F [454°C]. They feature accuracy of ±1% of reading, ±0.5% of full scale and repeatability of ±0.5% of reading with flow rates as low as 0.25 SFPS up to 1000 SFPS [0.07 NMPS to 305 NMPS] and 100:1 turndown.

This meter’s outputs and user interface choices are extensive to interface with virtually any control system and/or set-up or configuration devices. Standard outputs include dual, NAMUR NE43 compliant 4-20 mA analog outputs, HART (version 7), Modbus 485 and a USB port. Foundation Fieldbus or PROFIBUS PA or DP can be optionally added. The optional backlit LCD display provides digital and bar graph readouts of the flow rate and temperature, totalized flow, alarms, diagnostics feedback and even a user-defined label/tag field.

The ST80 Series transmitter enclosure is NEMA 4X/IP67 rated, selectable for NPT or metric
conduit port threading and is available in both aluminum and stainless steel and may be remotely located up to 1000 feet [305 m] apart from the flow element. The instrument also carries an independent, thirdparty evaluated SIL compliance.

#PAuto #FCI

User-friendly modular gas analyser for the biogas market!

Eaton has launched a new ‘next generation’ MTL GIR6000 biogas analyser to help ensure reliable, accurate measurement of gases in biogas production. The MTL GIR6000 gas analyser is the first truly modular biogas analyser, requiring minimal maintenance and enabling process engineers and biogas plant managers to reduce downtime and improve their processes.

“Our newest modular gas analyser is designed to meet and exceed the measurement needs of the biogas industry,” says Iain Gordon, Gas Analysis Product Line Manager at Eaton’s Crouse-Hinds Division. “With more than 30 years of experience in gas analysis, our team has developed a simple-to-use, high performance fit-and-forget solution, which enables process managers and engineers to increase uptime, with low cost of ownership.”

The MTL GIR6000 analyser uses an innovative modular concept that makes it user-serviceable and reduces lifetime service costs through quick and easy maintenance procedures that require no special tools or training. As a result, service engineer site visits are largely avoided with the guidance of the built-in self-diagnostic routines and pre-configured intelligent sensor modules.

The gas sensor modules can be individually replaced – simply slide in and lock with an automatic seal integrity check – which helps to ensure minimal downtime, increased process efficiency and reduced operational maintenance cost.

The analyser can measure up to six gases, including methane, oxygen and hydrogen sulphide, and is designed with dedicated sensor modules and long-life, established sensor technology to provide continuous, accurate and reliable readings. The integrated platform concept makes it easy to upgrade the MTL GIR6000 analyser to meet future demands as the plant’s measurement needs evolve.

The MTL GIR6000 analyser is designed to be secure and reliable. It requires key-lock access and PIN-codes to change the key parameters making the data safe. Setting up the unit on-site is facilitated by the large bright 7-inch LCD display and rugged keypad as well as an intuitive menu-driven structure. The display provides a clear visual warning when there is a system fault or when a sensor is reaching the end of its life-cycle, allowing users to predict or plan maintenance requirements. Data is transmitted to the plant host system through a number of communication methods, allowing live real-time data to be monitored remotely.

The MTL GIR6000 analyser is an integrated IP65 weatherproof solution and is ATEX approved for Zone 2 Hazardous Areas for installation flexibility around the biogas plant.

User-friendly gas analyser for launch next month!

A next generation gas analyser dedicated to the anaerobic digestion and biogas market at the AD & Biogas Show 2014 (2-3/7/2014, Birmingham, GB).  Visitors to the Eaton’s Crouse-Hinds stand will be the first to see the company’s innovative MTL gas analyser, which is the first truly modular solution and is expected to bring significant cost savings to gas measurement.  In addition, visitors can meet experts from MTL to learn more about hazardous area electrical equipment and how it is used to help meet ATEX safety certification requirements on a Biogas plant.

“The anaerobic digestion and biogas industry has been demanding a more user-friendly solution in the market, and our modular gas analyser is specifically designed to meet and exceed that need,” says Iain Gordon, Gas Analysis Product Line Manager at Eaton’s Crouse-Hinds Division. “With more than 30 years of experience in gas analysis, our team has developed a simple-to-use, high performance, fit-and-forget solution, which enables process managers and engineers to increase uptime and reduce operational costs.”

MTL GIR6000 is Eaton’s first gas analyser dedicated to the biogas market and uses sensor technology initially developed to provide continuous and reliable online gas measurement in the oil and gas industries.  The company is now extending its hazardous area knowledge and experience built on protecting equipment in the oil and gas industries to the biogas markets.

An expert will also be on hand to answer queries on hazardous area safety around the Biogas plant, enhancing safety and ensuring that plants meet the standards required for measurement and control in the hazardous area.  For more information on the new easy-to-use MTL GIR6000 gas analyser and to book a hazardous area discussion visit Hall 3 stand C031 at AD & Biogas trade show 2014, or contact mtlenquiry@eaton.com.

MTL products, part of the portfolio from Eaton’s Crouse-Hinds business, provide leading electronic instrumentation and protection capabilities for the process control industries.  Key applications include intrinsic safety, fieldbus, industrial networking, surge protection, HMI and visualisation, gas analysis and alarm management.

Biogas always under control!

OPTISONIC 7300 Biogas is a dedicated flowmeter for biogas applications from Krohne. The device is a specialised version of the OPTISONIC 7300 ultrasonic gas flowmeter for process gas applications.

Biogas presents a number of challenges to flow measurement such as low pressure and low flow rates and changes in gas composition: it contains 50-70 vol% of methane depending on the bio feedstock and process. The remaining part is CO2 (30-50 vol%) and small amounts of H2S, O2 and N2. While further downstream the gas may be compressed to 100 mbarg, the pressure is typically only 50-60 mbarg when measuring raw biogas e.g. directly after the fermentation. Here, biogas is also saturated with water and when the gas cools down, 5-6 vol% of free liquid water may appear in the pipeline. Temperature typically ranges from little over ambient temperature up to 50°C / 122°F. Backflow may appear in this applications, also scaling of bacteria can occur in the flowmeter. Also, process conditions are variable, e.g. when measurement is done directly after the fermentation, sudden temperature drops can occur when new sludge is fed into the fermentation tank.

Various flow measurement principles have been tested in these applications: while DP flowmeters (orifice plates) are not used due to the high pressure drop provided, Vortex flowmeters struggle with very low pressures and flow velocities, and thermal mass flowmeters are limited when water is present in the gas. Although ultrasonic is the only principle that is able to measure backflow, ultrasonic flowmeters are challenged by high damping of the acoustic signals by CO2 and high water content. In combination with a high price in relation to the other principles this has limited their use for biogas so far.

The unit has been specially designed to overcome the limitations of the ultrasonic principle here: while its signal transducers provide a stronger ultrasonic signal into the gas, its specialised signal processing allows for a better detection of small, strongly dampened acoustic signals. This and the mechanical design of transducers and transducer pockets makes the measurement insensitive to liquid water and biological scaling.

OPTISONIC 7300 Biogas features a maintenance-free full bore flow sensor without any moving parts. As H2S provides a corrosive solution when dissolved in water, the measuring tube is made of stainless steel 1.4404/316L and transducers are made of NACE-approved grade 29 Titanium for maximum corrosion resistance. OPTISONIC 7300 Biogas is equipped with lap joint flanges to lower its overall weight as biogas does not present high pressures and sometimes only plastic piping is used. The measurement accuracy is specified at 1% of actual measured flow rate, when calibrated with air, starting from 1 m/s / 3.28 ft/s flow velocity. When 2 % accuracy is sufficient, dry calibration can be selected as alternative at a significantly lower price.

Since the methane content of biogas may vary, it may be required for the operation of the biogas facility to know the exact methane content, e.g. when used as fuel for gas engines in a CHP unit. It features a built-in temperature sensor that in combination with the measured velocity of sound, enables direct measurement of methane content via calculation of the molar mass. OPTISONIC 7300 Biogas can also provide calculation of gas flow volume to standard conditions by using an additional pressure sensor. The electronics also include diagnostics to validate the functions of the flowmeter and the process. For output of the measured values, 4…20mA and pulse outputs are available. HART and Modbus (optional) are included for field communication.

OPTISONIC 7300 Biogas is certified for use in explosive areas (zone 1). As in general no pressure drop is allowed in biogas pipelines, the device is available in common line sizes DN50, 80, 100, 150, 200 / 2, 3, 4, 6 and 8".

• Krohne products are marketed in Ireland by DWN Instrumentation.