Biomethane Production

BIOMETHANE PRODUCTION FROM MUNICIPAL ORGANIC WASTE
A PROCESS AND EQUIPMENT DESIGN REPORT
IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE
BACHELOR OF SCIENCE IN CHEMICAL ENGINEERING
BY:
KRISTIAN F. ABAD
JUSTINE DAQUIOAG
JEANNIE Q. TAMAYAO
JOCELLE VILLAMOR
JANUARY 2, 2018
LETTER OF TRANSMITTAL
December 20, 2017
Engr. CAESAR POBRE LLPITAN

Instructor
Chemical Engineering Department
Cagayan State University
Dear Engr. Llapitan:
We are submitting herewith our design report entitled “Biomethane and Fertilizer
Production from Municipal Organic Wastes” as a partial fulfilment of the Chemical
Engineering Process and Equipment Design course requirement. The purpose of this
report is to identify and complete an appropriate process design that would allow
efficient production of biomethane and fertilizer with municipal organic wastes as raw
material.
The design report includes an overview of the process and product information, the
process description containing flow diagrams and piping and instrumentation, and
material and energy balances. Finally, the process and equipment design and the health,
safety, and environment considerations are also discussed and presented.
We hope that this report will merit your approval.
Respectfully yours,
Kristian F. Abad
Justine Daquioag
Jeannie Q. Tamayao
Jocelle Villamor
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TABLE OF CONTENTS
LETTER OF TRANSMITTAL ................................................................................................. 1
EXECUTIVE SUMMARY ....................................................................................................... 5
INTRODUCTION ..................................................................................................................... 1
1.1 Product Information ......................................................................................................... 1
1.1.1 Methane ..................................................................................................................... 1
1.1.2 Fertilizer..................................................................................................................... 1
1.2 Product Properties ....................................................................................................... 1
1.2.1 Methane ..................................................................................................................... 2
1.2.2. Fertilizer.................................................................................................................... 2
1.3.3 Gas Separation by Pressure Swing Adsorption ......................................................... 4
1.4 Process Selection .............................................................................................................. 5
1.5.1 Methane ..................................................................................................................... 6
1.5.2 Fertilizer..................................................................................................................... 7
1.6 Environmental Issues ....................................................................................................... 7
REFERENCES .......................................................................................................................... 8
Points ......................................................................................................................................... 9
TECHNICAL STUDY............................................................................................................. 11
2.1 Design Objective ............................................................................................................ 11
2.2 Design Synthesis ............................................................................................................ 11
Points ....................................................................................................................................... 17
Material and Energy Balance ................................................................................................... 19
3.1 Material Balance Calculation ......................................................................................... 19
3.1.1 Material Balance Around Pressure Swing Adsorption ............................................... 19
3.1.2 Material Balance Around H2S Scrubber ................................................................. 21
3.1.3 Material Balance Around Condenser ...................................................................... 23
3.1.4 Material Balance Around the Digester .................................................................... 25
3.1.5 Material Balance Around Pasteurizer ...................................................................... 26
3.1.6 Material Balance Around Shredder ......................................................................... 27
3.1.7 Material Balance Around Rotary Drum Reactor .................................................... 28
3.2 Energy Balance Calculation ........................................................................................... 30
3.2.1. Energy Balance Around Feed Preheater ................................................................. 30
3.2.2 Energy Balance Around Digester ............................................................................ 30
3.2.3 Energy Balance Around Condenser ........................................................................ 31
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3.2.4 Energy Balance Around Digestate Cooler............................................................... 33
3.2.5 Energy Balance Around CO2-CH4 Cooler ............................................................. 33
Points ....................................................................................................................................... 36
PIPING AND INSRUMENTATION DESIGN....................................................................... 38
4.1 WATER STORAGE TANK .......................................................................................... 40
4.2 SHREDDER ................................................................................................................... 41
4.3. MIXING TANK ............................................................................................................ 42
4.4 DIGESTER..................................................................................................................... 43
4.5 CONDENSER ................................................................................................................ 44
4.6 SCRUBBER ................................................................................................................... 45
4.7 PRESSURE SWING ADSORPTION ............................................................................ 46
4.8 CLARIFIER ................................................................................................................... 47
4.9 Fertilizer Storage Tank ................................................................................................... 48
4.10 Methane Storage Tank ................................................................................................. 49
REFERENCES ........................................................................................................................ 51
Points ....................................................................................................................................... 52
HEALTH, SAFETY AND THE ENVIRONMENT ................................................................ 54
5.1 Risk assessment .............................................................................................................. 54
5.1.1 Material Safety Data Sheets .................................................................................... 55
5.2 Government regulations ................................................................................................. 64
5.2.1 Methane ................................................................................................................... 64
5.2.2 Fertilizer................................................................................................................... 66
5.3 Hazard and Operability Studies...................................................................................... 68
5.3.1. Anaerobic Digester ................................................................................................. 68
List of main chemical/material involved in this process: ................................................. 68
5.3.2. Condensers.............................................................................................................. 69
5.3.3. Storage Tanks ......................................................................................................... 70
5.3.4. Shredder .................................................................................................................. 70
5.3.5 Scrubber ................................................................................................................... 71
5.3.6 Adsorption Column ................................................................................................. 71
5.3.7 Pasteurizer ............................................................................................................... 72
5.3.8 Rotary Drum Reactor............................................................................................... 73
5.4 Pollution prevention ....................................................................................................... 73
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5.5 Life Cycle Analysis ........................................................................................................ 74
5.5.1 Life Cycle Inventory ................................................................................................ 74
5.5.2 Life Cycle Impact Assessment ................................................................................ 76
REFERENCES ........................................................................................................................ 77
Points ....................................................................................................................................... 79
APPENDIX .............................................................................................................................. 81
EQUIPMENT DESIGN ........................................................................................................... 86
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EXECUTIVE SUMMARY
Methane is a valuable energy source and is regarded as a high class alternative for
fossil fuel. A digestate that is produced by anaerobic digestion is a potent plant fertilizer.
With the appropriate application of anaerobic digestion and the selection of an economically
effective process design, the design of the process of producing biomethane and fertilizer
from biomass is developed.
The central purpose of the study is to develop a new design adapted from various
alternative designs under which the process chosen will be feasible for biomass specifically
municipal solid wastes to produce methane and fertilizer.
In Chapter 1, the product information, properties, and demand, alternative designs,

process selection, and environmental considerations are discussed. The product demand
shows that the consumption of natural gas in the Philippines is increasing for the past years.
Also, based on the alternative designs and process selection, the process scheme is designed
by adapting the design of pressure swing adsorption and the process of anaerobic digestion.
In Chapter 2, the technical studies which includes the design objectives and the
design synthesis of biomethane production are explained. The synthesis and modification
shows the selection of the process equipment that are to be used to fulfill the objective of the
study. This includes the digester, pasteurizer, shredder, rotary drum reactor, condensers,
scrubber, pressure swing adsorption columns, and storage tanks.
In Chapter 3, the appropriate material and energy balances around each equipment
are shown as calculated. The summary of the data calculated can be found in the appendix.
In Chapter 4, the process equipment design is further defined through block and
process flow diagrams and piping and instrumentation. The manipulated and controlled
variables involved in each equipment is also shown.
In Chapter 5, the safety, health, and environment considerations are discussed. This
includes the material safety data sheets for methane and fertilizer to monitor the risk
assessment and government regulations in the Philippines concerning the production of
methane and fertilizer and the process involved. It also consists of HAZOP studies around
each equipment, pollution prevention and control, and a brief and qualitative life cycle
analysis. The LCA shows that the overall environmental performance of methane production
v
is strongly dependent on the environmental impacts of the substrate provision, the methane
yield, the energy input and source for the digestion process, and direct emissions from the
process and the use of digestates
vi
CHAPTER 1
INTRODUCTION
This chapter will discuss the product information, properties, and demand, alternative
designs, process selection, and environmental considerations. The product demand for natural
gas consumption in the country will be determined. Furthermore, the final process scheme
will be designed based on the selected alternative design and the process that will be chosen.
An overview of environmental issues is also discussed.
1.1 Product Information
1.1.1 Methane
Methane is a colorless, odorless, and flammable gas which is obtained
commercially from natural gas and biogas refinement. It is non-toxic but is considered
as a powerful greenhouse gas with greater detrimental effect than carbon dioxide.
However, methane is a valuable energy source and is regarded as a high class
alternative for fossil fuel.
The method commonly incorporated for the production of methane is anaerobic
decomposition of organic materials. The wide range of applicability of this gas in the
process industry includes its use as a fuel to drive a turbine for electricity generation
and as a heat source for steam production. Its utilization is not limited on the industry
but also covers global fuel necessities due to its low cost, low pollutant emission, ease
of handling, and availability.
1.1.2 Fertilizer
The digestate is a substance that is rich in nutrients and is produced by
anaerobic digestion. Its volume is around 90-95% of the digester feed and the nutrients
present in the feedstock remained in the digestate as none is present in the biogas
(NNFCC). Since the digestate is composed of the degraded materials made by
microorganisms, the nutrients are more available than when it is a raw slurry which
makes it a potent plant fertilizer.
1.2 Product Properties
1
1.2.1 Methane
Methane is the simplest hydrocarbon with a chemical formula of CH4. It is a
colourless and odourless gas which burns with a blue flame. At room temperature, it is
a gas that is less dense compared to water. It has a melting point of -182.5 °C and a
boiling point of -161.6°C. Methane is not soluble in water and does not burn at liquid
phase unless subjected to a high pressure. Its calorific value is 50MJ/kg which is
comparable to the calorific value of diesel fuel which is 45MJ/kg.
1.2.2. Fertilizer
The digestate which is a product of anaerobic digestion contains nutrients like
nitrogen, phosphorus, and potassium which are necessary for farming. Typically the
digestate is composed of 8% total solids and 92% water. The total solids is comprised
of 24% inorganic and 76% organic solids. The organic matter can help in building up
the humus content in the soil. Since no nutrients are lost during anaerobic digestion,
farmers can close the nutrient cycle and reuse these vital minerals (European Biogas
Association, 2013).
1.3. Alternative Designs of Biogas Production

1.3.1 Biogas Production from Thin Grain Stillage
In the production of bio-ethanol large amounts of stillage residues are produced.
This stillage is energy-rich and can be used as a biogas substrate for biogas production.
The block diagram shown on Figure 4.1 was obtained from the study of
Moestedt et al. It makes use of waste crops and stillage for the production of methane.
Incorporating this process design would enable bio-ethanol industries to
transform their waste into a valuable gas which in turn could be used to fuel their
energy-requiring equipment. This scheme also yields a high methane purity which is at
an average of 97%. However, the high levels of nitrogen and sulphate in thin stillage
makes it a complicated feedstock. The high nitrogen and sulphate concentration result
in inhibition of the microbial activities, and thus the digestion process.
This design also includes digestion that operates in mesophilic conditions which
makes digestion process longer compared to the anaerobic digestion of biomass to
biogas that operates in thermophilic conditions. A low product yield could be
experienced in this scheme and in order to handle the long process of digestion, two
digester are constructed to increase the production rate. The fact that digesters are huge
2
process tanks, higher installation and maintenance cost is expected in adapting this
design.
Another is that a water scrubber is used for methane refinement which involves
the absorption of carbon dioxide to water. The possible risk of this method is that
residual amount of water and carbon dioxide may be present in the product stream,
therefore, corrosion on pipeline is likely to occur. Pipeline corrosion would result to
combustible methane leakage which is damaging to the industrial facility.
Storage for
Water
energy crops Digester 1
Scrubber
Hammer mill
Gas buffer and
Gas Storage
Water Digestate
(97% methane)
Cooling
Storage for Feeding

Digester 2
stillage Tank
Digestion
Bio-fertilizer
Lagoon
Figure 1.1. Biogas Production from Thin Stillage
1.3.2 Production of Biogas and Fertilizer from Human Waste and Landfills
The block diagram shown in Figure 4.2 was adapted from the design of the
Kurobe City Sewage Treatment Plant in Kurobe, Japan. Human wastes and landfill are
considered as a substrate for this scheme.
The scheme proposed is a possible solution for lessening human wastes which
imposes negative effects to the environment. The production of two kinds of fertilizer
which is the solid and liquid organic fertilizers that have different applicabilities in
agriculture is also achieved in this process design.
However, as we are dealing with human wastes and landfill as raw materials,
handling is a critical factor to be considered. Unlike in biomass to biogas technology,
there must be a more intensive waste handling process or a waste treatment system that
will be able to fully treat the raw materials and this would imply that additional
equipment must be used. Another is that to facilitate movement of the raw materials
especially the human waste, heavy dilution is necessary. Because of this, additional
3
cost of operation is incurred for the dilution process. Normally, biomass is inherently
safer to treat than human wastes because it doesn’t carry human pathogens.
Another drawback of this scheme is the process used in refining the biogas
which is the humidification process. This method makes use of heat exchanger to dry
the gas and a cyclonic water separator to condense the water. By this, additional
operating and maintenance cost for the industry is incurred. Adapting humidification
process for methane refinement may also result to pipeline corrosion due to the
possibility of the presence of residual corrosive gases in product stream.
Human
and Grit Primary Aeration Final Settling
Screen
Landfill Chamber Settling Tank Tank Tank
Waste
Clarifier
Thickened
Biogas
Sludge Humidifier
Storage Tank
Storage Tank
Solid
Anaerobic Organic
Mixing Tank Clarifier Pasteurizer Dehydrator
Digester Fertilizer
Liquid Organic
Fertilizer Tank
Figure 1.2. Biogas and Fertilizer Production from Human Waste and Landfills
1.3.3 Gas Separation by Pressure Swing Adsorption

Biogas exists as a mixture of different gases with methane and carbon dioxide
as main components. To obtain methane in its pure form, different separation processes
are employed, one of which is the pressure swing adsorption shown in Figure 4.3. The
process scheme is obtain from an article made by Energy Professional Symposium,
2017.
Pressure swing adsorption method involves the adsorption/desorption of

unwanted gases like carbon dioxide and hydrogen sulfide on zeolites or activated
carbon at different pressure levels. This process yields to a high purity methane
product which is at an average of >98%.
Adapting pressure swing adsorption in the process design would ensure the removal
of corrosive gases in the product stream because of it high purity product yield. This
would in turn give no risk on pipelines which would minimize methane leakage that
4
would impose danger to the industrial facility. Minimal corroded pipe replacement is
also ensured in this design process.
Biogas Pressure Swing Storage Tank

50-70% Separator Compressor Cooler Adsorption Separator Gas Drier >98%
methane Column methane
Recirculation
Flash Tank
Water
Figure 1.3. Methane Purification by Pressure Swing Adsorption
1.4 Process Selection
The aim of biomethane production is to reduce environmental waste issues and

generate efficient and high purity methane which can be a substitute to non-renewable
energies in a fast and economical way. This production also aims to use reduced
number of equipment operating at optimum conditions without requiring high energy
and causing much impact to the environment.
At present, several designs for biogas production have been established. Some
designs prefer to use mesophilic digesters but it was observed that this requires longer
period of degradation of waste to produce biogas. Other designs use a different
scrubber to reduce the amount of gases mixed like hydrogen sulphide, vapour, and
carbon dioxide. The reactants needed to scrub the mixed gases are costly and inefficient
to remove large amounts of corrosive gases that might impose damaging effect in
industrial operation, thus, it is important to choose which has the highest efficiency and
which is cheaper.
Thermophilic digester is used and established in this design since it is more
reliable and a more accepted mode of fermentation. It can provide added benefits in
terms of biogas production. This kind of digester design produces high quality methane
and has a good performance due to its shorter period of digestion and higher
composition of methane produced. Lesser retention time means greater production of
biogas.
5
Biogas requires refining treatment in order to obtain pure methane which is the
energy-carrying gas. Cleaning of gases are capital-intensive and operates in multi-
stages which needs high maintenance and energy. In this design, Pressure Swing
Adsorption and the use of condensers are applied to remove moisture, carbon dioxide,
and hydrogen sulphide.
1.5 Product Demand
1.5.1 Methane
Most countries are leading campaigns to find alternative sources of fuel. The
drastic depletion of the world petroleum reserves, the increased emission of combustion
products, and the pressing need to minimize the solid environmental waste worldwide,
have stimulated the search for these alternatives. Biofuel like methane is one of the
viable renewable energy resources that is regarded as a solution to these problems.
Since methane production utilizes wastes as raw material, its demand greatly
increases due to the world’s increasing waste quantity. As shown in Figure 5.1, the
consumption of consumers in natural gas in the Philippines for the past few years is
drastically increasing. The solution offered by methane utilization to the problems
stated above had increased its economic viability. Therefore it would be a good choice
to enter in the methane production business since it is highly demanded.
Natural Gas Consumption

in the Philippines
160000
140000
Consumption, million m3
120000
100000
80000
60000
40000
20000
Year
Figure 1.4 Previous Consumption of Natural Gas in the Philippines

(Source: Department of Energy)
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1.5.2 Fertilizer
Organic fertilizer like digestate is also highly in demand at present because of its
capability of resolving numerous environmental issues. According to Anaerobic
Digestion and Bioresources Association, 1 ton of artificial fertilizer replaced with
digestate saves 1 ton of oil, 108 tons of water, and 7 tons of CO2 emissions.
From a global survey on organic farming 2007 carried out by the Foundation
Ecology and Agriculture SOEL and the Research Institute of Organic Culture FiBL,
organic agriculture is developing rapidly and is now practiced in more than 120
countries of the world. Almost 31 million hectares are currently managed organically
by at least 633, 891 farms with 129, 927 farms in Asia (Philippine Organic Agriculture
Information Network, 2005). Therefore, marketing the organic fertilizer produced from
the anaerobic digestate would find its position in world economic trade and could be
competent product in the field of farming.
1.6 Environmental Issues
Anaerobic digestion has been scrutinized for some environmental impacts such
as the potential for increased ammonia emissions and the creation of air contaminants
associated with biogas combustion when compared to other alternative methods of
waste management. While anaerobic digesters may reduce some environmental effects
of other waste operations, they do not mitigate all environmental impacts in large scale
operations such as water quality and air emissions. Most of the environmental impacts
reported for an anaerobic digestion system were acidification potential and
eutrophication potential. The acidification and eutrophication potentials are respectively
25 and 12 times higher than for natural gas in a combined heat and power plant. The
impacts are influenced by the type and source of feedstock, digestate storage and its
application on land. The full environmental footprint of anaerobic digestion is complex
and will vary depending on the application, management, and design specifications of
the project.
7
REFERENCES
1. Adviento, Ramirez, Tannagan (2013) Production of Methane Gas from Municipal Solid
Waste ©2013 College of Engineering, Cagayan State University, Tuguegarao City
Cagayan
2. Galamay, Gutierez, Siringan, Tacazon (2017) Methane Production from Municipal
Solid Wastes ©2017 College of Engineering, Cagayan State University, Tuguegarao
City Cagayan
3. Datul, Dizon (2015) Production of Renewable Natural Gas (Biomethane) from Pig and
Chicken Manure ©2015 College of Engineering, Cagayan State University,
Tuguegarao City Cagayan
4. Bingemer, H. G., Crutzen, P. J. (1987). The Production of Methane from Solid Wastes.
Journal of Geophysical Research
5. Jørgensen, P.J. (2009). Biogas – green energy. Aarhus University.
6. Biomethane Regions. Introduction to the Production of Biomethane from Biogas.
7. Mes, T.Z.D., Stams, A.J.M., Reith, J.H., Zeeman, G. (2002). Methane production by
anaerobic digestion of wastewater and solid wastes.
8. Grande, C., Santos, M., Rodrigues, A. (2011). Pressure Swing Adsorption for Biogas
Upgrading. Ind. Eng. Chem.
9. Fact Sheet, Anaerobic Digestion. (2015). European Bioplastic.
10. Themelis, N.J. (2002). Anaerobic Digestion of Biodegradable Organics in Municipal
Solid Wastes. Columbia University.
11. Uddin, M., Mojumder, S. (2011). Biogas Production from Municipal Waste: Prospect
in Bangladesh. Multidisciplinary Journals in Science and Technology, Journal of
Selected Areas in Renewable and Sustainable Energy.
12. Al Seadi, T., Rutz, D., Prassl, H., Kottner, M., Finsterwalder, T., Volk, S., & Janssen,
R. (2008). Biogas Handbook. Denmark.
13. FNR. (2013). Biogas an introduction. Fachagentur Nachwachsende Rohstoffe e.V.

(FNR).
14. Zhang, R., Gekas, P., Zhu, B., Lord, J., & Choate, C. (n.d.). Biogas Production from
Municipal Organic Solid Wastes. California.
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TECHNICAL REPORT ASSESSMENT RUBRIC
In
Process Equipment Design
Name of Student: _____________________________________________________________

Title of Report: __________________________________________________________
Topic Unacceptable Marginal Acceptable Exceptional

Points
(Weight) (0) (1) (2) (3)
Organization Sequence of information is Work is hard to follow as Information is presented in Information is presented in
& difficult to follow. No there is very little a logical manner, which is a logical, interesting way,
Style apparent structure or continuity. easily followed. which is easy to follow.
continuity.
Purpose of work is stated, Purpose of work is clearly Purpose is clearly stated
Weight: 8 Purpose of work is not but does not assist in stated and assists the and explains the structure
clearly stated. following work. structure of work. of work.
Content No grasp of information. Uncomfortable with At ease with content and Demonstration of full
& Clearly no knowledge of content. able to elaborate and knowledge of the subject
Knowledge subject matter. explain to some degree. with explanations and
Only basic concepts are elaboration.
No questions are answered. demonstrated and
Weight: 10 No interpretation made. interpreted.
Figures, Tables Work is illegible, format Mostly consistent format. Format is generally Format is consistent
and Graphs changes throughout, e.g. consistent including throughout including
font type, size etc. Figures and tables are heading styles and captions. heading styles and captions.
legible, but not convincing.
Weight: 8 Figures and tables are Figures and tables are Figures and tables are
sloppy and fail to provide neatly done and provide presented logically and
intended information. intended information. reinforce the text.
9
Equations Work fails to follow Many departures from Minor departures from Departmental format is
Weight: 2 required format. Failed to required format. Many required format or observed in all equations.
use MS Equation Editor. problems with citation of inconsistencies between Citations consistent with
Words used instead of equations. Many symbols equations. Minor problems format
symbols. not properly defined. with citation of equations.
Some symbols not properly
defined.
Spelling Numerous spelling and Several spelling and Minor misspellings and/or Negligible misspellings
& grammatical errors. grammatical errors. grammatical errors. and/or grammatical errors.
Grammar
Weight: 5
Readability Report plagued with Many instances of “noise.” Some instances of “noise.” Report was free of “noise
Weight: 4 distractions and ‘noise.” issues.”
References No referencing system Inadequate list of Minor inadequacies in Reference section complete
used. references or references in references. and comprehensive.
Weight: 3 text.
Consistent referencing Consistent and logical
Inconsistent or illogical system. referencing system.
referencing system.
TOTAL
Instructor/Rater: Engr. CAESAR P. LLAPITAN
10
Chapter 2
TECHNICAL STUDY
This chapter will explain the technical studies which includes the design objectives and
the design synthesis of biomethane production. This will also show the process equipment
selection and the corresponding objective and function of each equipment.
2.1 Design Objective
The objective is to design a feasible organic municipal solid waste processing plant that
produces high purity bio-methane. By-product utilization must be also considered in the
design.
2.2 Design Synthesis
The conversion of organic solid waste into methane is undertaken in an anaerobic

digester.
Organic
Anaerobic
Solid Methane
Digester
Waste
This is an idealized process because methane is not the sole gas produced. Other
gases generated are carbon dioxide, hydrogen sulphide and moisture. It is desired to
design a process for the production of bio-methane from organic municipal solid waste.
Diagram Modification
2.2.1 As stated in chapter 1, thermophilic condition is to be administered in the
digestion process to lessen the digestion time. The anaerobic microorganism does not
consume the organic waste in its solid form. It easier for the microbe to breakdown the
organic solid waste if it is in its fluid like state. Therefore, dilution of waste is needed to
increase digestion rate and facilitate the movement of solid waste. A pasteurizer would
be a suitable equipment to administer this operation.
11
Biogas
Organic Sludge CH4
Anaerobic
Solid Mixing Tank CO2
Digester
Waste H2 S
H2 O
2.2.2 To achieve better homogeneity and easier dilution and transport of organic waste,
size reduction of waste must be incorporated. This done by the use of a shredder
machine.
Water
Biogas
Shredded CH4
Organic Sludge Anaerobic
Shredder Waste Mixing Tank CO2
Solid Digester
Waste H2S
H2O
2.2.3 Various inorganic waste that are not digested by the anaerobic microbes are
present in the waste feed. This must be removed since it is not needed for digestion and
also to prevent overloading and clogging of waste in the pipes and equipment. Many
biological treatment plant makes use of a rotary drum reactor to separate and prepare
the organic materials in municipal solid waste to be used as feedstock for anaerobic
digestion. The rotary drum reactior involves the mechanical segregation of waste by
density and size.
Water
Organic
Solid Biogas
Municipal Shredded CH4
Rotary Drum Waste Sludge Anaerobic
Solid Shredder Waste Mixing Tank CO2
Reactor Digester
Waste H2S
H2O
Inorganic
Solid
Waste
12
2.2.4 Methane is not the sole product of anaerobic digestion. The product stream is also
composed of carbon dioxide, hydrogen sulphide and water vapour which are corrosive
in nature and may degrade the transportation pipeline.
For the removal of water vapor the product stream is passed through a condenser. This
process liquefies the water vapor which allow its separation from the gases.
Water
Organic
Solid Shredded
Municipal Sludge Biogas
Rotary Drum Waste waste Anaerobic Gas
Solid Shredder Pasteurizer Condenser
Reactor Digester Mixture
Waste
Inorganic
Water
Solid
Waste
For the removal of hydrogen sulphide, the gas stream is contacted with an amine
solution in a scrubber column.
Water
Sulfur
Biogas Rich
CH4 Biogas Solution
Organic CO2 CH4
Solid H2S CO2
Shredded
Municipal Rotary Drum Waste Sludge Anaerobic H2O H2S
Shredder Waste Mixing Tank Condenser
Solid Reactor Digester
Waste
Sulfur
Scrubber
Inorganic Water
Solid
Waste Biogas
Amine
CH4
Solution
CO2
2.2.5 Pressure swing adsorption is incorporated in the further purification of methane.

This method uses a zeolite adsorbent and would give a methane purity yield of >98%.
13
Water
Sulfur
Biogas Rich
CH4 Biogas Solution
Organic CO2 CH4
Solid H2S CO2
Shredded
Waste
Sulfur
Water Scrubber
Inorganic Methane
Solid CH4
Waste Amine
Sulfur Biogas
CH4 Solution
Scrubber
CO2
CO2
2.2.6 For easy transport and storage, the methane produced is liquefied by passing it
through a condenser.
Water
Sulfur
Biogas Rich
CH4 Biogas Solution
Organic CO2 CH4
Solid H2S CO2
Shredded
Waste
Sulfur
Liquified Water Scrubber
Methane Methane
Inorganic Storage Tanks Condenser CH4
Solid
Waste Amine
Sulfur Biogas
CH4 Solution
Scrubber
CO2
CO2
2.2.7 It is observed that there are unutilized outflows in the process. Our goal is to
generate a process that would use this materials to come up in a more economic design.
The condensed vapor from the condenser could be used for the dilution process in the
pasteurizer. The digestate produced from anaerobic digestion can readily be utilized as
a fertilizer due to its high nutrient content. The sulphur rich solution in sent into a
solvent recovery facility where the amine solution is recycled back and the hydrogen
sulphide could be sold to other chemical industry where it is reprocessed to obtain
elemental sulphur. Lastly the carbon dioxide could also be sold to other industries for
certain applicability.
14
The overall process flow diagram of Biomethane Production and Fertilizer is:
Water
Sulfur
Biogas Rich
CH4 Biogas Solution
Organic CO2 CH4
Solid H2S CO2
Shredded
Waste
Sulfur
Liquefied Scrubber
Methane Methane
Inorganic Storage Tanks Condenser CH4
Solid
Waste Amine
Sulfur Biogas
CH4 Solution
Scrubber
Liquefied CO2
CO2
Storage Tanks Condenser
CO2
Figure 2.1 Block flow diagram of Biomethane and Fertilizer Production from organic
solid waste.
15
Figure 2.2 Process Flow Diagram of Biomethane and Fertilizer Production from Organic Solid Waste
16
In
Name of Student: ______________________________________________________________
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(Weight) (0) (1) (2) (3)
continuity.
&Knowledge Clearly no knowledge of content. able to elaborate and knowledge of the subject
subject matter. explain to some degree. with explanations and
Weight: 10 No questions are answered. demonstrated and
No interpretation made. interpreted.
17
required format. Failed to required format. Many required format or observed in all equations.
Weight: 2 symbols. not properly defined. with citation of equations.
defined.
Grammar
Weight: 5
distractions and ‘noise.” issues.”
Weight: 4
No referencing system Inadequate list of Minor inadequacies in Reference section complete
References used. references or references in references. and comprehensive.
text.
Weight: 3 Inconsistent or illogical system. referencing system.
referencing system.
TOTAL
18
Chapter 3
Material and Energy Balance
This chapter deals primarily with calculations of inflows and outflows of the different
equipment. The values to be obtained from the calculations are fundamental to the control of
processing, particularly in the control of yields of the products. The major principle involved
in this chapter are the material and energy balance.
Material balance is the application of the law of conservation of mass that is used to
calculate mass flow rates of different streams entering or leaving chemical or physical
processes. The measurements provide basis for optimization, scale up and regulatory
reporting. The basis for the material balance of this study is the product requirement of
100,000 kg per day of biomethane using organic solid wastes.
Energy balance is based on the law of conservation of energy which helps in
examination of the various stages of a process, over the whole process and even extending
over the total production system from the raw material to the finished product. In the
production of biomethane, energy balances around heat exchangers and major equipment are
computed.
3.1 Material Balance Calculation
3.1.1 Material Balance Around Pressure Swing Adsorption
Basis:
a. Average biomethane content before adsorption (x1CH4) is 73% (Oliveira F et al., 2015)
b. Total CO2 recovery (Air Products and Chemicals Inc.,2010)
c. Daily biomethane production (P1) of 100,000 kg.
19
P1
Pressure Swing
m1
Adsorption
x1CH4 =0.73
x1CO2 =0.27
P2
Figure 3.1.Material balance around pressure swing adsorption.
Degrees of Freedom Analysis
+3 Unknown Variable
- 3Independent Equations
= 0 degree of freedom (the problem is solvable)
Overall material balance:
m1  P1  P2
m1  100,000  P2
Methane Balance
m1 x 1CH4  P1 x P1CH4
m1 (0.73)  100,000(1)
m1  136,986.3014 kg H 2 S free biogas

day
Carbon Dioxide Balance
m1 x 1CO2  P2 x P2CO2
(136986.3014 )(0.27)  P2 (1)
P2  136986.3014(0.27)  36,986.30137 kg carbon dioxide
day
20
3.1.2 Material Balance Around H2S Scrubber
Basis:
a. H2S composition of biogas is less than 1% and is negligible (Al Seadi T. et al., 2008),
but still H2S scrubber is necessary to prevent its accumulation in pipes and equipment.
b. m1  136986.3014 kg H 2 S free biogas

day
Assumptions:
a. H2S composition of biogas is 1%
b. Total removal of H2S
c. Amine solution flow rate (m3) of 20,000 kg per day.
m4 m2
x4H2S x2CH4 =0.725
x2CO2 =0.265
x2H2S=0.01
H2 S
Scrubber
m3 m1
x1CH4 =0.73
x1CO2 =0.27
Figure 3.2. Material balance around H2S scrubber.
+3 Unknown Variable
- 3Independent Equations
21
m 2  m 3  m1  m 4
m 2  20,000  136986.3014  m 4
m 2  m 4  116,986.3014
Methane Balance
m 1 x 1CH4  m 2 x 2CH4
(136986.3014)(0.73)  m 2 (0.725)
m 2  137,931.0345 kg dry biogas
day
m 2  m 4  116,986.3014
m 4  137931.0345  116,986.3014  20,944.7331 kg scrubbed stream
day
Amount of sulphur present in the biogas stream
amount of sulfur  amount of sulfur scrubbed  0.01(m 2 )

amount of sulfur  amount of sulfur scrubbed
amount of sulfur  0.01(137931.0345)
amount of sulfur  1379.310345kg sulfur/day
Mass fraction of sulphur in the scrubbing solvent
weight sulfur 1379.310345

x 4H2S    0.065855
weight of scrubbing solvent 20,944.7331
22
3.1.3 Material Balance Around Condenser
Basis:
a. Methane composition of biogas after digestion is 60% (m5) (source: Krich et al., 2005).
kg dry biogas
b. m 2  137,931.0345 day
Assumption:
a. Total removal of water.
m5 Condenser m2
x5CH4 =0.60 x2CH4 =0.725
m6
Figure 3.3. Material balance around condenser.
+2 Unknown Variable
- 2 Independent Equations
m5  m2  m6
m 5  137931.0345  m 6
Methane Balance
m 5 x 5CH4  m 2 x 2CH4
m 5 (0.60)  137931.0345(0.725)
m 5  166,666.6667 kg biogas
day
23
Amount of condensed water
m6  m5  m2
m 6  166,666.6667 - 137,931.0345
m 6  28,735.6322 kg condensed water
day
Weight fraction of water at the feed stream
28,735.6322
x 5H2O   0.172414
166,666.667
24
3.1.4 Material Balance Around the Digester
Basis:
a. Digestate volume is 90% of the feedstock (source: NNFCC)
kg biogas
b. m 5  166,666.6667 day
Anaerobic
m7 m5
Digester
x5CH4 =0.60
x5CO2 =0.37
x5H2O=0.02
x5H2S=0.01
Figure 3.4. Material balance
m8 around anaerobic digester.
+2 Unknown Variable
m 7  m5  m8
m 7  166,666.6667  m 8
m 8  0.90m 7
m 7  166,666.6667  m 8
m 7  166,666.6667  0.90m 7
0.10m 7  166,666.6667
m 7  1,666,666.667 kg sludge
day
Amount of digestate
m 8  0.90m7  0.90(1,666,666.667)  1,500,000 kg digestate

day
25
3.1.5 Material Balance Around Pasteurizer
Basis:
a. The input feed to the digester must be diluted until the composition is 65% water
(European Biogas Association).
b. m 7  1,666,666.667 kg sludge
day
m9
m10 Pasteurizer m7
Figure 3.5. Material balance around pasteurizer.
+2 Unknown Variable
m10  m 9  m 7
m10  1,666,666.6667  m 9
Amount of water needed for dilution
m 9  0.65m 7  0.65(1,666,666.6667)  1,083,333.333 kg water

day
Amount of solid waste
m 10  166,666.6667  m 9  1,666,666.6667  1,083,333.333  583,333.3337 kg solid waste

day
26
3.1.6 Material Balance Around Shredder
Basis:
a. m 10  583,333.3337 kg solid waste

day
Assumption:
a. No solid waste losses upon shredding.
m11 Shredder m10
Figure 3.6.Material balance around shredder.
+1 Unknown Variable
m 11  m 10
m 11  583,333.3337 kg organic solid waste
day
27
3.1.7 Material Balance Around Rotary Drum Reactor
Basis:
a. Municipal solid waste comprises of 67% organic waste and 33% inorganic waste
(Thitame SN et al.,2010)
b. m 11  583,333.3337 kg organic solid waste

day
Assumptions:
a. Complete segregation of inorganic and organic wastes.
b. No solid waste losses upon segregation.
Rotary Drum
m12 m11
Reactor
x12organic=0.67
x12inorganic=0.33
m13 rotary drum reactor.

Figure 3.7. Material balance around

+2 Unknown Variable
m 12  m11  m 13
m 12  583,333.3337  m13
Organic Waste Balance
m12 x 12organic  m11
m11 583,333.3337
m12    870,646.7667 kg municipal organic waste
x 12organic 0.67 day
Inorganic Waste Balance

m 13  m 12 x 12inorganic
m 13  870,646.7667(0.33)  287,313.433 kg inorganic waste

day
28
28,735.63kg/day
Water
583,333.37
kg/day Biogas Sulfur Rich
CH4 Solution
Biogas
Organic CO2
CH4
870,646.767 Solid Waste H2S
Shredded CO2
Sludge H2O
Municipal kg/day Rotary Drum
Shredder
Waste
Mixing Tank
Anaerobic
Condenser
H2S
Solid Waste Reactor 583,333.37 1,083,333.33 166,667.67 Digester 166,667.67 137,931.0345
kg/day kg/day kg/day kg/day kg/day
287,313.43
kg/day
Sulfur Scrubber
Fertilizer
150,000 kg/day
Inorganic
Solid Waste
Amine
Solution
20,000 kg/day
Methane
100,000 kg/day
CH4
136,698.3014
Pressure Swing kg/day
Adsorption
Biogas
CH4
CO2
CO2 36,986.30137kg/day
Figure 3.8 Quantitative Flow Diagram of Biomethane and Fertilizer Production from Organic Solid Wastes.
29
3.2 Energy Balance Calculation
3.2.1. Energy Balance Around Feed Preheater
kg kg
m10  1,666,666.6667  19.29
day s
kg H 2 O kg
m9  1,083,333.333  12.5386
day s
Q  mC p T Biomass  mC p T Water
kg  kJ  kg  kJ 
Q  19.29 1.8 328.15  298.15K  12.5386  4.182 328.15  298.15K
s  kgK  s  kgK 
Q  2614.753kW
3.2.2 Energy Balance Around Digester
1 11 13
C6 H 12O5  H 2 O  CH 4  CO2
2 4 4
30
kJ kJ
H f ,CO2  74.85  8.9436
mol kg
kJ kJ
H f ,CH 4  393.52  4.6781
mol kg
kJ kJ
H f ,C6 H12O5  288.82  16.0456
mol kg
kJ kJ
H f , H 2O  733  4.4695
mol kg
H rxn  H f ,CO2  H f ,CH 4  H f ,C6 H12O5  H f , H 2O
H rxn 
11
 4.6781  13  8.9426  1  16.0456   4.4695
4 4 2
kJ
H rxn  29.439
kg
kg  kJ  kJ
Q  m7 H rxn  1666666.667   29.439   49.065 10 6
day  kg  day
Q  567.88kW
3.2.3 Energy Balance Around Condenser
C p,CH 4  19.87 103  5.021105 T  1.268 108 T 2  111012 T 3
C p,CO2  36.11103  9.233 105 T  2.887 108 T 2  7.464 1012 T 3
C p,H2O( g )  35.51103  1.547 105 T  1.268 108 T 2  3.292 1012 T 3
31
nin Ĥin nout(mol/s Ĥout(kJ/kmol
(mol/s) (kJ/kmol ) )
CH4 72.338 ĤCH4 72.3379 0
CO2 36.282 ĤCO2 9.9777 0
H2O(g 18.477 ĤH2O - -
H2O(l - - - 0
Table A.1. Ĥin and Ĥout of Biogas Composition at Ref: CH4, CO2, H2O(l) (25 °C, 1 atm)
CH 4 (25C,1atm)  CH 4 (25C,0.05 atm)  CH 4 (55C,0.05 atm)
  m3  101.325 
H CH 4  VCH 4 1  0.05  
328.15
C p ,CH 4 dT  0.0289 (1  0.05) atm   1.1051
298.15 mol  1000 
 kJ
H CH 4  1.1079
mol
CO2 (25C,1atm)  CO2 (25C,0.05 atm)  CO2 (55C,0.05 atm)
  m3  101.325 
H CO2  VCO 2 1  0.05  
328.15
C p ,CO 2 dT  0.029 (1  0.05) atm   1.4029
298.15 mol  1000 
 kJ
H CO 2  1.4057
mol
32
 
H H 2O  H H 2O v,1atm, sat ' d   1.8864
kJ
mol
Q  H   ni H i   ni H i
out in
Q  72.338 1.1079  36.28241.4057  18.4771.8864
Q  166.00kW
3.2.4 Energy Balance Around Digestate Cooler
kg kg
mdigestate  1,500,000  17.361
day s
kJ
C p ,( digestate)  1.55
kgK
kg  kJ 
Q  mC p T  17.361 1.55 298.15  328.15K
s  kgK 
Q  807.291kW
3.2.5 Energy Balance Around CO2-CH4 Cooler
nCH 4  72.338 kmol

s
33
nCO 2  9.729 kmol
s
kJ
H A min e  8.5978
kmol
kJ
H CH 4  5.1404
kmol
Q  nH CH 4  nH CO 2
Q  455.494kW
34
3.3. Utility Requirement
1. Water Consumption
The water used in biomethane and fertilizer production can be gained from surface
water, rivers or reservoir. The pH and temperature of the process water is adjusted as it enters
the digester. Water treatment is used to maintain the quality of water needed for the different
process, many of which with have its own individual technical requirements. Water is also
recycled and reused to lessen the consumption. It is undergoes cooling/ heating treatments
and purification treatment for specific applications.
2. Energy Consumption
Electricity for biomethane production is supplied by a private generating company
and by the plant itself. The biomethane produced during the process can be generated to
become electricity. Gas turbine generators are mostly used converters to produce electricity.
It can convert up to 9MW of electricity depending on the size of the turbine and amount of
biogas available.
35
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Name of Student: ______________________________________________________________
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Points
(Weight) (0) (1) (2) (3)
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36
defined.
Grammar
Weight: 5
Weight: 4
text.
referencing system.
TOTAL
37
Chapter 4
PIPING AND INSRUMENTATION DESIGN
The piping and instrumentations diagram (P&ID) provides a schematic representation
of the piping process control and instrumentation which shows the functional relationships
among the system components. Instrumentations are used in industrial plants to measure
process variables such as temperature, flow, pressure, pH, liquid level and composition. By
using instruments, values of these variables can be recorded continuously and controlled.
A standard set of symbols is used to modify the diagram. The primary schematic
drawing is used for laying out a process control installation. It shows all of piping including
the physical sequence of pipes and valves, branches, instrumentations and control interlocks.
In the anaerobic digester, which is the heart of the process, the environment is
controlled by changing the steam temperature and pressure entering for the microorganisms
to digest well. Flow controllers and level transmitters are the instruments mostly used to
maintain safety and for economic purposes. Flow of fluids are controlled using valves and
pumps.
This chapter aims design a P&ID in each equipment and to the overall process design in
order to have smooth operation and maintain the product quality during the process by
regulating the variables and control the disturbances in the process.
A. Valves Selection
Ball valves are suitable for gas installation and are used as shutoff or isolating
system. The most reliable valves are chrome-plated ball valves. Butterly and globe
valves are used to control substrate and gas flows, respectively. The main gas valve is
installed close to the anaerobic digester.
38
Table 4.1. Valves used in biomethane production from organic solid wastes.
Valve Streams Role

Butterfly Biogas Gas and vapour flow
Biomethane control
Recycled CO2
Globe Process Water Flow control other than

Slurries gas
Ball Shutoff and isolating
Pressure Relief Valve Prevention of vessel
rapture
B. Pumps
Pumps are required to bridge differences in height between the levels of
slurry-flow through the biogas unit. They can also be required to mix the substance to
speed up slow-flowing substances. Biogas pumps are designed to transfer natural gas
created by the decomposing of organic material. They are usually heavy duty due to
the abrasive nature of biogas.
Single-stage centrifugal pumps are used in the biomethane production
considering its properties and handling risks.
39
4.1 WATER STORAGE TANK
Figure 4.1. Piping and Instrumentation Diagram of Water Storage Tank
Feedback control strategy is used in this system. The water coming from the
reservoir is pumped to the storage tank. Controller valves are installed to regulate the
flow of water coming inside the tank and the flow of water distributed around the plant.
Through the manipulation of the flow of water, the level of water in the storage tank
and volume of water in the outflow stream is controlled.
Table 4.1 Variables Involved in Water Storage Tank

Input Output Control System
(Manipulated) (Controlled)
Inflow of water Water Level Feedback

Outflow of Water Volume of Water
40
4.2 SHREDDER
Figure 4.2 Piping and Instrumentation Diagram of Shredder
The first pre-treatment process of organic waste is shredding where the waste is
reduced to maximum of 12mm. Feedback control strategy is used regulate the volume
of waste being conveyed in the shredder and a check valve to know the level of
shredder to serve as warning device whenever there is choking.
Table 4.2 Variables Involved in Shredder

Inflow of waste Waste level Feedback
41
4.3. MIXING TANK
Figure 4.3 Piping and Instrumentation Diagram of Mixing Tank
The shredded waste is then conveyed into the mixing tank where it is partially
dissolved in water to help microorganisms digest properly. Flow controller is installed
to regulate the flow of sludge pumped from the tank. Also, the level of the slurry being
mixed in the tank is observed through the check valve.
Table 4.3 Variables Involved in Mixing Tank

Outflow of Sludge Sludge level in the digester Feedback
42
4.4 DIGESTER
Figure 4.4 Piping and Instrumentation Diagram of Anaerobic Digester
The main operation in the biomethane production is the anaerobic digestion. The
sludge is fed in the digester where it is heated to reach thermophilic temperature (52°C)
for the microorganisms to start digestion. Steam coming in the digester is controlled to
regulate the temperature and pressure inside the reactor. Level controller is also
installed to ensure that the level of slurry does not reach the feed level of the reactor.
The bottoms product is the digestate which is filtered through the clarifier to separate
the solid into liquid fraction. The biogas product containing CH4, CO2, H2S and H2O
are withdrawn at the top of the digester.
Table 4.4 .Variables Involved in Anaerobic Digester

Flow of Steam Reactor Temperature & Feedback

Pressure
Digester Level
Flow of Sludge
43
4.5 CONDENSER
Figure 4.5 Process and Diagram of Anaerobic Digester
From the digester, the biogas is directed into a condenser where it is treated to
remove the excess water vapour. The temperature of condenser is maintained at 25°C
by controlling the flow of cooling water entering. The condensate is recycled to be
added in the mixing tank while the unsaturated biogas is subjected into another
purification process through the scrubber.
Table 4.5 Variables Involved in Condenser

Flow of Cooling Condenser Temperature Feedback

Water
44
4.6 SCRUBBER
Figure 4.6 Process and d Diagram of Anaerobic Digester
The scrubber scrubs the hydrogen sulphide present in the biogas through methyl
amine solution. The solvent enters the top of the scrubber while the biogas enters at the
bottom. As the solution and the gas come in contact, hydrogen sulphide is left resulting
in rich sulphur and MEA solution. Flow controllers are used to avoid overflow of any
solution and maintain a smooth counter-current flow from both streams.
Table 4.6 Variables Involved in Condenser

Flow of methyl amine Solvent level Feedback

Flow of Biogas Volume of biogas
45
4.7 PRESSURE SWING ADSORPTION
Figure 4.7 Process and d Diagram of Pressure Swing Adsorption
Pressure Swing Adsorption is operated under moderate temperature and pressure.
The multi effect columns reduce consumption by continuous gas compression in order
for the gas pressure to be used subsequently by the other columns.
The first column is operated at 90psi which purifies the biogas at about 96%. From
the degasification of the fourth column, the pressure in the second column is lowered
at 45 psi. This pressure is then reduced to atmospheric pressure and the released gas
flows back to the digester so that CH4 can be recovered.
In the third column, the operational pressure lowered from 15 to 1 psi that caused
the desorbed gas (CO2) to be vented in the atmosphere. The resulting product of the
pressure swing adsorption is 98-99% biomethane which is stored for selling or
operational purposes.
46
Table 4.7 Variables Involved in Pressure Swing Adsorption
Flow of gases Pressure and temperature of Feedback

the columns
4.8 CLARIFIER
Figure 4.8 Process and d Diagram of Clarifier
The digestate leaving the reactor is a mixture of solid slurry and liquid solution
which must be separated in the clarifier. The flow of digestate is manipulated to control
the level in the clarifier in order to avoid overflow. The liquid solution flowing out is
the fertilizer while the solids left inside the clarifier at recycle slurry which is pumped
back to the digester for another digestion process since it still contains live
microorganisms that are involved in the anaerobic digestion.
Table 4.8 Variables Involved in Clarifier

Flow of Digestate Clarifier level Feedback
47
4.9 Fertilizer Storage Tank
Figure 4.9 Process and d Diagram of Fertilizer Storage Tank
The separated liquid fractions are stored on site in a storage tank prior to utilization
on the farmer’s land. Level of the tank is controlled by manipulating the inflow of
fertilizer being stored in the tank.
Table 4.9 Variables Involved in Fertilizer Storage Tank

Flow of Fertilizer Storage Level Feedback
48
4.10 Methane Storage Tank
Figure 4.10 Process and d Diagram of Fertilizer Storage Tank
Methane is hazardous, thus, it is required to maintain a standard temperature and
pressure before releasing to the market for safety precautions. It is stored as liquid in
high pressure at refrigerated containers. The storage tank is designed especially for the
properties of methane. It is maintains a surrounding suitable for methane by
manipulating the heat and pressure around the tank.
Table 4.10 Variables Involved in Fertilizer Storage Tank

Heat Tank temperature Feedback

Pressure Physical state of methane
49
ST-101 ST-102 ST-103 S-101 MT-101 R-101 C-101
Water Storage Fertilizer Storage Methane Storage Shredder Mixing Tank/ Reactor Clarifier
Tank Tank Tank Pasteurizer
E-101 SC-101 T-101 T-102 T-103 T-104 E-102
Condenser Sulfur Scrubber Column Tray 1 Column Tray 2 Column Tray 3 Column Tray 4 Condenser 2
Figure 4.11. Overall Piping and Instrumentation Flow Diagram of Biomethenation Process from Biomass
50
REFERENCES
1. Al-Zuahiri, F., Pirozzi, D., Ausiello, A., Florio, C., Turco, M., Micoli, L., Zucarro, G.,
Toscano, G. (2015). Biogas Production from Solid State Anaerobic Digestion for
Municipal Solid Wastes. The Italian Association of Chemical Engineering, 43. DOI:
10.330/cET1543402.
2. Bingemer, H. G., Crutzen, P. J. (1987). The Production of Methane from Solid
Wastes. Journal of Geophysical Research, 92, 181-2187
3. Couper, J. R., W., Fair, J., Walas, S.M. (2012). Chemical Process Equipment
Selection and Design, 3rd ed. Elsevier Inc, Jordan Hill, Oxford OX2 *DP, UK.
4. Forster-Carnier, T., Isaac, R., Perez, M., Schvatz, C. (2012). Anaerobic Digestion
Pretreatments of Substrates. Biogas Production, 1-26.
Upgrading. Ind. Eng. Chem. Res., 50, 974-985.
6. Kern, D. (1950) Process Heat Transfer. McGraw Hill Book Company, Inc.
7. Monnet, F. (2003). An Inroduction to Anaerobic Digestion of Organic Wastes. Final
Report, Scotalnd.
8. Porisson, J. (2015). Biogas Upgrading Using Amine Absorption. Thesis, Univerisity
of Iceland.
51
In
Name of Student: ______________________________________________________________
Title of Report: __________________________________________________________

Points
(Weight) (0) (1) (2) (3)
continuity.
52
defined.
Grammar
Weight: 5
Weight: 4
text.
referencing system.
TOTAL
53
Chapter 5
HEALTH, SAFETY AND THE ENVIRONMENT

This chapter will present considerations for the health and safety of workers and
environmental limitations. Material safety data sheets for methane and fertilizer and
individual HAZOP study for each equipment are provided. Other environmental constrictions
such as pollution prevention and life cycle analysis is also discussed.
5.1 Risk assessment
Methane is a colorless and odorless natural gas. It is lighter than air, therefore
it tends to rise from the biogas slurry. Methane is non-toxic and is unlikely to be a
concern in well-ventilated room and open space. However, inside an emptied digester
chamber the concentration can reach dangerous levels and may prove to be
deleterious for workers cleaning the digester tank.
Since methane is explosive in air at a concentration between 5% and 15%, the

digesters contain an explosive atmosphere at some point during the start-up phase.
When its concentration rises above 15%, the risk of explosion is considerably
reduced.
Methane plants process large quantities of combustible and toxic gases, which
pose increased fire and explosion hazards in case of faults in design, material or
control. Methane is highly flammable and forms explosive mixtures in combination
with the oxygen in the air. Therefore explosion protection is very important in
methane plants.
The sites of biogas production may become sources of pathogens if

improperly operated and managed. Even though the digestion process does reduce the
number of pathogens particularly at higher operating temperatures, it fails to eliminate
them under lower temperature. Moreover, the time and temperature required to
eliminate or reduce microbial hazards may vary depending on climate and the specific
management practices of an individual operation Proper hygienic procedures need to
be enforced to avoid pathogen-driven diseases.
54
5.1.1 Material Safety Data Sheets
Table 5.1 MSDS for METHANE.

1. PRODUCT IDENTIFICATION
Name METHANE
Chemical Name Methane
Chemical Formula CH4
Synonyms Methyl Hydride
Chemical Family Paraffins
CAS No. 74-82-8
UN No. 1971
ERG No. 115
Hazchem Warning 2A flammable gas
2. HAZARDS IDENTIFICATION
Main Hazard Methane poses hazards to personnel through its
flammability.
Chemical Hazards No known effect

Biological Hazards No known effect
Eye Contact No harmful effect.
Skin Contact No harmful effect.
Inhalation Methane is nontoxic. It can, however, reduce the
amount of oxygen in the air necessary to support life.
Exposure to oxygen-deficient atmospheres (less than
19.5 %) may produce dizziness, nausea, vomiting, loss
of consciousness, and death. At very low oxygen
concentrations (less than 12 %) unconsciousness and
death may occur without warning. It should be noted
that before suffocation could occur, the lower
flammable limit for Methane in air will be exceeded;
causing both oxygen deficient and an explosive
atmosphere.
Ingestion Not applicable
55
3. FIRST AID MEASURES
The conscious person who becomes aware of nausea and pressure on the forehead
and eyes should go promptly to an uncontaminated area and inhale fresh air or
oxygen. However, in the event of massive exposure the victim may become
unconscious or symptoms of asphyxiation may persist. In that case the person should
be removed to an uncontaminated area, and given artificial respiration and then
oxygen, after breathing has been restored. Treat symptomatically thereafter.
4. FIRE FIGHTING MEASURES

Extinguishing Media Dry chemical, carbon dioxide, or water.
Fire And Explosion Hazards: Most cylinders are designed to vent contents
when exposed to elevated temperatures. Pressure
in a cylinder can build up due to heat and it may
rupture if pressure relief devices should fail to
function. Ventilate all confined spaces using
forced-draught if necessary. Ensure that all
electrically powered equipment is flameproof.
Emergency Actions If possible, shut off gas flow at source. Evacuate
area. Post warning to prevent persons from
approaching with lit cigarettes or open flames.
Using water, keep all cylinders in the vicinity of
the fire cool. Remove cylinders from the vicinity
of the fire if possible. Allow small fires on
cylinders to remain burning if they are not posing
a hazard.
Protective Clothing Exposed fire fighters should wear approved self-
contained breathing apparatus with full mask.
5. ACCIDENTAL RELEASE MEASURES

Personal Precautions As Methane is a simple asphyxiant care should be
taken when entering confined spaces where leaks
have occurred. Do not enter any potentially
hazardous area with any source of ignition such
as a lit cigarette or match.
Environmental Precaution Methane does not pose a hazard to the
environment. An explosive gas-air mixture could
be formed when leaks occur, so eliminate all
forms of ignition.
56
Small Spills Small leaks should be extinguished by shutting
off the source of supply, e.g. closing the valve on
the cylinder, or tightening the gland nut. If unable
to stop small leaks the cylinder should be moved
into the open, well away from any source of
ignition. Should a small leak have ignited, use a
multi-purpose dry powder or carbon dioxide
extinguisher. Should there be no extinguisher
available, a welder’s glove or heavy cloth, soaked
in water may be used to extinguish the flame.
Large Spills Stop the source if it can be done without risk.
Eliminate all sources of ignition and static
discharges. Restrict access to the area until
completion of the clean-up procedure. Post
relevant warning signs. Wear adequate protective
clothing when working near the source of leak.
Ventilate the area using forced-draught if
necessary. Ensure that all equipment is
flameproof.
6. HANDLING AND STORAGE

Proper ventilation should be installed in all work places to ensure safe and healthy
working atmosphere free from hazardous or toxic chemicals.
7. EXPOSURE CONTROLS/PERSONAL PROTECTIONS

Occupational Exposure No known effect.
Hazards
Engineering Control Measures Engineering control measures are preferred to reduce
exposures. General methods include mechanical
ventilation, process or personal enclosure, and control
of process conditions. Administrative controls and
personal protective equipment may also be required.
Use a suitable flameproof ventilation system separate
from other exhaust ventilation systems. Exhaust direct
to outside. Supply sufficient replacement air to make up
for air removed by exhaust system.
Personal Protection Use self-contained breathing apparatus when fighting
large fires.
Eyes Use safety glasses when working with cylinders.

Hands Use suitable protective gloves when working with
cylinders.
57
Feet Wear protective footwear when working with cylinders.
8. PHYSICAL DATA
Molecular Weight 16.04
Appearance Colorless
Odor Odorless
Boiling Point -161.5 °C
Freezing Point -182.2 °C
Vapor Pressure Permanent, noncondensable gas
Solubility In Water 3.3 ml gas per 100 ml
Specific Gravity 0.554
Viscosity Not applicable
Flash Point -306 °F (-187.8 °C)
Flammable Limit 5.0% - 15%
9. STABILITY AND REACTIVITY DATA

Stability Stable
Conditions To Avoid Cylinders should not be exposed to temperatures
in excess of 125 °F (52 °C). Keep sparks and
flame away from cylinder and under no
circumstances allow a torch flame to come into
contact with any part of the cylinder. Never test
for leaks with a flame. Use soapy water when
testing for leaks. Never use cylinders as rollers or
supports, or for any purposes other than the
storing of Methane.
Materials To Avoid Oxygen, Halogens and Oxidizers
Hazardous Decomposition No hazardous compounds are formed when

Products Methane /air mixtures burn.
10. TOXICOLOGICAL INFORMATION

Acute Toxicity No known effect.
Skin and Eye Contact No known effect.
58
Chronic Toxicity No known effect.
Carcinogenicity No known effect.
Reproductive Hazards No known effect.
11. ECOLOGICAL INFORMATION

As Methane is lighter than air, it will disperse rapidly in open areas. It does not pose
a hazard to the ecology.
12. DISPOSAL CONSIDERATIONS

Disposal Methods Small amounts may be blown to the atmosphere
under controlled conditions. No sources of
ignition should be in the vicinity. Large amounts
should only be handled by the gas supplier.
Disposal of Packaging The disposal of containers must only be handled
by the gas supplier.
13. REGULATORY INFORMATION

EEC Hazard Class Flammable gas
Risk Phrases R12 Extremely flammable
Safety Phrases S2 Keep out of reach of children
S9 Keep container well ventilated
S16 Keep away from source of ignition
S33 Take precautionary measures against static
discharges
Table 5.2 MSDS for FERTILIZER.

1. PRODUCT IDENTIFICATION
Name Liquid Fertilizer
Common Chemical NPK compound fertilizer
Name
Chemical Formula Not applicable
Chemical Family Not applicable
59
Composition Ammonium Nitrate: 39.4%
Information
Urea: 30.6%
Water: 30.0%
Typical N-P-K Composition
Total Nitrogen as N: 28%
Total Phosphorus as P2O5: 0%
Total Potassium: 0%
Fertilizer salts, inert ingredients: 72%
CAS No. Ammonium Nitrate: 6484-52-2
Urea: 57-13-6
Water: 7732-18-5
2. HAZARDS IDENTIFICATION
Main Hazard Normally classified as non-hazardous
Chemical Hazards No known effect

Biological Hazards No known effect
Eye Contact may cause irritation in case of prolonged or
repeated contact
Skin Contact may cause irritation in case of prolonged contact
Inhalation Large quantities of dust containing this product
may cause irritation of the nose and airways; the
symptoms include sore throat and cough.
Ingestion No toxic effects in case of small quantities, in

large quantities it may cause gastrointestinal
disorders, and, in extreme cases (especially in
children) it may cause methaemoglobinaemia, the
“blue baby syndrome” and cyanosis (blueness
around the mouth).
3. FIRST AID MEASURES

First aid instructions are provided depending on the relevant exposure routes.
Skin contact: rinse the affected area with plenty of water. Remove contaminated
clothing and shoes. In case symptoms occur, seek medical advice.
Eye contact: rinse/irrigate eyes with plenty of water for 10 minutes; if irritation
60
persists, seek immediately medical advice.
Ingestion: in case of ingesting the product, rinse mouth with water (only if the victim
is conscious). Do not induce vomiting. In case symptoms occur, seek medical advice.
Inhalation: in case of inhaling the product, remove victim to fresh air. In case
symptoms occur, seek medical advice.
Recommendations: Remove the victim from the area contaminated with dust or gas,
keep the victim at rest in a warm area, even in the absence of symptoms; administer
oxygen, especially in case of blueness around the mouth; artificial respiration must
be used only as a last resort, in case of prolonged exposure.
4. FIRE FIGHTING MEASURES

Extinguishing Media Water.
Fire And Explosion Hazards: The substance may be explosive in contact with
flammable or organic substances, or if it is
confined during the fire. In case of fire, hazardous
decomposition products may be generated, such
as nitrogen oxides
(NO, NO2 etc.), ammonia (NH3), amines.
Emergency Actions Special measures are not necessary. Wear
adequate protection equipment. Use a self-
contained breathing apparatus.
Protective Clothing Special measures are not necessary. Wear
adequate protection equipment. Use a self-
contained breathing apparatus.
5. ACCIDENTAL RELEASE MEASURES

Personal Precautions In case of great danger, the surrounding area must
be evacuated. Avoid inhaling toxic fumes by
standing up wind from the fire. The personnel
involved in emergency situations must wear duck,
dust resistant equipment, chemical aggression
resistant boots and protection mask.
Environmental Precaution Avoid contamination of the soil and groundwater
courses.
Small Spills Small spills can be safely neutralized with lime

stone or soda ash. Sweep up the absorbed material
and place in drum for field application or for
disposal. Then rinse area with water and absorb
with absorbent material
61
Large Spills For larger spills, contain the area with diking to
avoid contamination of water ways or rivers.
Then begin process of neutralization using lime
stone or soda ash
6. HANDLING AND STORAGE

Use adequate ventilation. A local exhaust ventilation system must be provided.
Avoid all possible ignition sources (spark or flame). Avoid contamination with any
source, including metals, dust or organic substances.
7. EXPOSURE CONTROLS/PERSONAL PROTECTIONS

Occupational Exposure No known effect.
Hazards
Engineering Control Engineering control measures are preferred to
Measures reduce exposures. Avoid high dust concentration
and provide ventilation when necessary.
Personal Protection Technical measures: provide a ventilation system,
where necessary.
Hygiene measures: do not eat, drink or smoke
while handling the product. Wash hands after
handling and before eating, smoking or using the
toilet, as well as at the end of the working period.
Personal protection during production activities:
breathing apparatus, protective mask
Eyes Use tight safety goggles (plastic frame,
polycarbonate lens) for chemical substances and
face mask (polycarbonate), in case of danger of
nitrate splashes.
Hands Use suitable protective gloves.
Feet Wear chemical and mechanical aggression
resistant boots, with anti-static properties that
allow usage in explosive environments (leather
with rubber soles)..
8. PHYSICAL DATA
Appearance White-gray; Granules
Odor Odorless
62
Boiling Point >210 °C; Decomposes before boiling
Vapor Pressure Negligible at room temperature
Solubility In Water Soluble
Viscosity Not applicable
Flash Point Not applicable, as the fertilizer includes a mixture
of inorganic solids
Explosive Properties Non explosive
Flammable Limit Does not self-ignite.
9. STABILITY AND REACTIVITY DATA

Stability Stable
Conditions To Avoid Avoid contact with bases or metals other than
stainless steel. Avoid adding water to acid and
excessive heat.
Materials To Avoid Strong oxidizing agents, strong bases and water
will produce hydrogen gas.
Hazardous Decomposition High heat can produce hydrogen gas and/or
Products phosphorus oxides.
10. TOXICOLOGICAL INFORMATION

Acute Toxicity Oral: >2000 mg/kg
Dermal: >5000 mg/kg
Skin and Eye Contact Slight potential; low
Chronic Toxicity No known effect.
Carcinogenicity Not by NTP or IARC
Reproductive Hazards No known effect.
11. ECOLOGICAL INFORMATION

Phosphoric acid has a low toxicity for aquatic life, however, this product can produce
hydrogen gas when added to water or around metals.
12. DISPOSAL CONSIDERATIONS
63
Collect and process when possible. Follow neutralization with limestone or soda ash
and field apply if possible. Check local and national regulations for disposal.
13. REGULATORY INFORMATION

NFPA Hazard Rating Non-flammable; Moderately reactive
Risk Phrases R8 Contact with combustible material may cause
fire.
R36 Irritating to eye.
Safety Phrases P210 – Keep away from heat/sparks/open
flames/hot surfaces. No smoking.
P220 – Keep/Store away from
clothing/combustible materials (lubricants, Diesel
fuel, oil, paints etc.)
P264 – Wash hands thoroughly after handling
P280 – Wear protective gloves (heat
resistant)/protective clothing (powder resistant
overalls)/tight safety goggles/ face mask S33 Take
precautionary measures against static discharges
5.2 Government regulations
5.2.1 Methane
According to Rule No. 5: Definition of Terms under Part I: General Provisions of
Circular No. 2002-08-005, “Natural Gas” refers to gas consisting primarily of
hydrocarbons, which at atmospheric conditions of temperature and pressure, are in a
gaseous phase and which have been identified under either a Service Contract or Gas
Sales and Purchase Contract as being primarily “Methane” with smaller quantities of
heavier fractions also being entrained.
64
GENERAL PROVISIONS
This Circular establishes the Rules and Regulations to be followed with respect to
supply, siting, design, construction, expansion, rehabilitation, modification, operation,
maintenance, safety and commercial arrangement of the Value Chain of the Philippine
Natural Gas Industry (PNGI). The State shall ensure that the Philippine Natural Gas
Industry, from its emerging state, will be developed into a matured market enabling the
PERMITS
For purposes of this Circular, the following Permits shall be issued in accordance
to an Application Guideline to be issued by the DOE:
a. Notice to Proceed (NTP)
b. Permit to Construct, Expand, Rehabilitate, Modify (PCERM)
c. Permit to Operate and Maintain (POM)
country to achieve greater energy security and sustainability.
STANDARDS CONSTRUCTION, OPERATION AND MAINTENANCE OF

NATURAL GAS FACILITY
Generally, multiple layers of protection are created by critical safety conditions, all of
which are integrated with a combination of industry standards and regulatory
compliance. Industry standards are written to guide industry and enable public
officials to efficiently evaluate safety, security, and environmental impacts of LNG
facilities and industry activities. Regulatory compliance should ensure transparency
and accountability in the public domain. The requirements for safety, primary
containment, secondary containment, safeguard systems, separation distance,
Industry Standards/Regulatory Compliance, Operational Safety and discontinuance
of operation standards, shall be applied across the LNG Value Chain, from
production, liquefaction, and shipping, to storage and re-gasification.
65
PRODUCT STANDARD
Quality: The Operator shall maintain the quality of gas supply to Customers in
accordance with the Philippine or Internationally Accepted Standards and ensure that
delivery of indigenous or imported LNG must always pass the purification
requirements from associated compounds unnecessary or damaging to the LNG
regasification facility.
Standard Conditions: Standard conditions for the purpose of this Circular shall
mean the conditions of Natural Gas at a temperature of 15.5 degrees Celsius (°C)
(288.15°Kelvin) and an absolute pressure of 0.101325 megapascals (Mpa) or 1013.25
millibars.
5.2.2 Fertilizer
The following information is obtained from the guidebook Fertilizer Regulatory
Policies and Implementing Guidelines published on 2013 by the Fertilizer and Pesticide
Authority in pursuant to Presidential Decree No. 1144 issued on May 30, 1977.
BASIC POLICIES
1. All fertilizer products, organic or inorganic, raw materials and ingredients for
fertilizer, which are imported or produced locally, should be registered with FPA.
2. The registration process carries with it pertinent requirements and presentation of

documentary evidence to support claims on the quality of the product and its
effectiveness to target crops.
3. The registration process likewise provides suitable guidelines for the registration of
all fertilizer products to assure farmers and end-users of their acceptable quality and
effectiveness as guaranteed by the manufacturer and/or importer before they are
marketed.
4. Registration requirements include the submission of product specification supported

by chemical analysis, mode of action, product type and the result of efficacy trials
conducted by an accredited and independent researcher. The set of data is evaluated by
a registration consultant.
5. With increasing market demand, a wide range of products are provided through 3
66
continued production of new grades, brands and types of locally produced and imported
fertilizers. Registration of these commercially processed fertilizers is therefore needed
to give greater assurance that the quality of each brand is maintained at the specified
standards (characteristics and effects) as claimed by the producer or importer.
6. Fertilizer handlers such as importers, distributors, exporters, bulk-blenders and

processors should register their products with FPA.
PRODUCT REGISTRATION
A. Full Registration – granted when all administrative and technical requirements are
satisfactorily complied with which includes two (2) seasons of efficacy tests with
significant results on a representative crop
B. Provisional or Conditional Registration – granted if there is only one season of

efficacy test with significant results on a representative crop.
TECHNICAL REQUIREMENTS
Organic Fertilizer
a. Chemical analysis of essential nutrients as claimed by the registrant from FPA

recognized laboratory.
b. Test for pathogens. Claims on the presence of beneficial microorganisms shall also
be specified and quantified.
c. Test for heavy metals if raw materials are from sewage sludge, mine tailings, etc.
d. Test for weed seeds by germination test. Weed seed should be absent but if this is
present, weight, population and identification should be done at the expense of the
registrant.
67
DECLARED PRODUCT COMPOSITION
For organic fertilizer, the permissible deviation shall be plus or minus five percent (5%)
of the minimum requirement.
5.3 Hazard and Operability Studies
5.3.1. Anaerobic Digester
List of main chemical/material involved in this process:

Sludge
Table 5.3.1 HAZOP Analysis for Digester.
Study Node Process Possible Possible Action Required

Parameters Deviation Causes Consequences
Accumulation of
Power failure;
nutrients; Add light indicators
None Defected
Inconsistent for sensed error
stirrer
concentration
Agitator Speed
Less viscous Less production of Add temperature
More
medium bacteria control system
More viscous Less production of Add temperature
Less
medium bacteria control system
Bacteria becomes
Low water
inactive; Add temperature
Low supply
Medium becomes control system
Exhaust temperature
Temperature highly viscous
Heater
High water Death of bacteria;
Add temperature
High supply Medium becomes
control system
temperature less viscous
68
5.3.2. Condensers
Biogas
Methane gas
Carbon dioxide gas
Table 5.3.2. HAZOP Analysis for Condenser.
Study Node Process Possible Causes Possible Action Required

Deviation
Parameters Consequences
Accumulation of
steam in digester; Schedule inspection
None Broken pipe
Loss of feed into and maintenance
condenser
Increase of steam
Condenser Flow in digester;
Low Scaling, Leaking Install check valve
Backflow of
material
Untreated steam Install bypass line

High pressure
High released to with manual valve
from digester
atmosphere
Fan motor
not Steam not Maintenance of the
No
functioning condensed fan motor
properly
Fan Speed Fan motor not Some steam
Maintenance of the
Low functioning released to
fan motor
properly atmosphere
Fan motor not Higher energy Maintenance of the

High functioning consumption fan motor
properly
69
5.3.3. Storage Tanks
Liquid methane
Liquefied carbon dioxide
Table 5.3.3. HAZOP Analysis for Storage Tanks.
Study Process Possible Causes Possible Action Required

Deviation
Node Parameters Consequences
Monitor the level

Tank runs dry; Pump cavitates;
Low of the reagent in
Leakage Reagent released
Level the tank
Tank Install level

High Too much feed Tank overflows
alarm
Temperature in Monitor the

Low Possible vacuum
the inlet is lower temperature
Temperature
Temperature of Tank fails; Monitor the
High
inlet is higher Fire/explosion temperature
5.3.4. Shredder
Organic solid waste
Table 5.3.4. HAZOP Analysis for Shredder.
Study Node Process Possible Possible Action

Deviation
Parameters Causes Consequences Required
Install purchase
Ununiformed alternative
Low Power failure
sizes power source
Shredder Speed
Controller Ununiformed Monitor the
High
fails sizes feed being fed
70
5.3.5 Scrubber
Biogas
Amine solution
Table 5.3.5. HAZOP Analysis for Scrubber.
Study Node Process Deviation Possible Possible Action Required

Parameters Causes Consequences
Scaling, Failure of gas Install check
Leaking engine, valve
Low mechanic
failure,
Flow corrosion
High pressure Untreated gas Install bypass

High from released to line with manual
Scrubber condenser atmosphere valve
Low Changed
temperature scrubbing
Low
of scrubbing properties
liquid Monitor the
Temperature
temperature
Failure of Abnormal
High scrubbing operation
agent conditions
5.3.6 Adsorption Column

CO2-CH4 Gas mixture
Table 5.3.6. HAZOP Analysis for Adsorption Column.
Study Node Process Deviation Possible Possible Action

Tubing may Desired Install check

be pinched extraction fails valve
Low due to
insufficient
Adsorption flow of input
Flow
Column Increase in The column Decrease speed
pumpspeed may overflow. of pump in
High order to
decrease flow
of water
71
5.3.7 Pasteurizer
Biomass
Table 5.3.7. HAZOP Analysis for Pasteurizer.

Shortage of Insufficient Provide a
heating heating in the flow
Low
medium tank diversion
valve
Temperature Uncontrolled Sterilization Monitor the
temperature temperature
High of the of the
heating heating
Pasteurizer medium medium
Low Desired Install a
pressure pasteurization flow-meter
Low
is not based pump.
Flow achieved
Too much Leakage Install a
High pressure booster
pump
72
5.3.8 Rotary Drum Reactor
Biomass
Table 5.3.8. HAZOP Analysis for Rotary Drum Reactor.

Header Breach of Install an
pipeline high pressure automated
leak or pipeline and low
rupture subsequent pressure
Low
pressure shutdown
reduction; system
potential fire
Rotary Drum or explosion
Pressure
Reactor
Header Potential Install a
pressure rupture of relief valve
operates reactor; or a control
High at a higher potential fire valve
pressure and explosion
than
required
5.4 Pollution prevention
During digestion itself there are low to no emissions of gases (0 - 1% or 0.5 –

8% of produced biogas) because the treatment occurs in closed containers and pipes
(Lyng et al. 2011; Jørgensen 2015; Fløan 2015).
Pollution to soil is caused by increasing levels in heavy metal concentration and

the remaining levels of chemical oxygen demand (COD) and biological oxygen demand
(BOD). High levels of these generates an anaerobic soil that is poor for life and has the
potential to continue to produce biogas, which will be released directly to the
atmosphere.
Pollution to water bodies comes in mainly two forms, leaching of nutrients from
agricultural spreading and COD and BOD of the leached material. The nutrient N and P
is a worldwide common problem due to agriculture and leaching from fields. There is a
big difference in leaching based on soil type (Bernstad & Jansen 2011).
73
Applying a good substrate mix and applying pasteurization, as a pre-treatment,
as a small codigestion benefits a fair assumption. Co-digestion can therefore result in a
higher biogas yield in form of degrability in addition to a stable and self-sustained
process. By securing zero leakage form digester and apply chemical scrubber as the
upgrading technology, would reduce direct GWP and increase the energy output in
form of biomethane applicable for grid or fuel purposes. Composting biofertilizer
would achieve the greatest decrease in impact for all impact categories.
5.5 Life Cycle Analysis
Methane from anaerobic digestion can either be burned directly in cogeneration

power and heat plants or can be used as substitute for or additive to natural gas.
The overall environmental performance of methane production is strongly

dependent on the environmental impacts of the substrate provision, the methane yield,
the energy input and source for the digestion process and direct emissions from the
process and the use of digestates (Börjesson & Berglund 2005). Actual biomass
substrates used in anaerobic digestion have different biogas yields due to their different
energy content.
5.5.1 Life Cycle Inventory

5.5.1.1. Raw materials acquisition
Biomass supply costs should be estimated and the supply potential analyzed to
determine the optimum amount that should be supplied to the plant. First, supply costs,
consisting of harvesting and transportation costs, should be estimated for the
components of MSW based on transportation distances. Second, supply models should
be created for all target municipalities to estimate marginal costs (MC) and average
costs (AC). Third, the amount of MSW should be estimated when MC and AC were set
at an expense appropriate under current garbage disposal conditions of the municipality
where the plant is supposed to be built.
5.5.1.2. Product uses and applications

Methane is an important source of hydrogen and some organic chemicals. It is
also useful in the testing of gas appliances which are to be used for natural gas areas.
Methane reacts with steam at high temperatures to yield carbon monoxide and
hydrogen; the latter is used in the manufacture
of ammonia for fertilizers and explosives. Other valuable chemicals derived from
74
methane include methanol, chloroform, carbon tetrachloride, and nitromethane. It is
also one of the raw materials used in the production of ethanol, methyl chloride,
methylene chloride, and is also used to produce ammonia and acetylene. High purity
methane is burned to form a high quality carbon black which is used in a variety of
electronic components and also widely used as a reinforcing agent in rubber used for
automobile tires.
After the production of the methane, the digested matter is usually spread as
fertilizer on agricultural land. This requires vehicles and machinery for transport and
spreading and it leads to ammonia emissions into air and heavy metal emissions into
soil. In the standard case, the environmental impacts from the digestate application are
allocated to the agricultural cultivation.
5.5.1.3. Product generation and distribution

Due to the fact that operators of biogas plants burn biogas in cogeneration units
in order to supply the anaerobic digestion unit with heat and electricity, only the
amount of biogas that is not required for covering the digestion unit’s heat demand can
be processed to produce biomethane. The heat consumption of the digestion unit is the
limiting factor, since the entire heat demand is met with the production of the
cogeneration unit in contrast to electricity that is not only consumed from the
cogeneration unit but also from grid.
BIOMASS
ELECTRICITY
ANAEROBIC
DIGESTION
PLANT
BIOGAS
HEAT COGENERATION
UNIT PRESSURE SWING
ADSORPTION
ELECTRICITY BIOMETHANE
DIGESTATE
APPLICATION APPLICATION APPLICATION
Figure 5.1: Biomethane and fertilizer production from biomass including the energy
inputs.
75
Fig. 5.5.1.3 shows the flow chart of biomethane and fertilizer production from
biomass including the energy inputs with the assumption that the biomass will produce
two valuable products which are the fertilizer and the biogas given that the biogas
amount required for providing the heat consumption of the biogas plant is sent to a
cogeneration unit and the remaining amount of biogas is goes through pressure swing
adsorption to produce biomethane.
5.5.2 Life Cycle Impact Assessment

The impact assessment phase consists of two mandatory actions: classification
and characterization. First, it is necessary to disaggregate it into impact categories
namely global warming, acidification, and human toxicity. Secondly, in the
characterization part, the potential impact of each emission or resource use should be
calculated, using certain scientific aggregation factors. The impact indicators
considered to be most suitable for describing processes involving agricultural practices
and implemented in several other biogas production LCAs are global warming,
eutrophication and acidification potentials (Pehme 2013; Moora 2009; Fuchsz &
Kohlheb 2015).
Firstly, global warming is the result of the accumulation of gases, such as CO2,
N2O (Nitrous Oxide), CH4 and halocarbons in the atmosphere. The proclaimed
consequences of the anthropogenic greenhouse effect include higher global average
temperatures, and changes in the global and regional climates (IPCC 2016).
Secondly, the rate and extent of eutrophication characterized as excessive plant

and algal growth due to the increased availability of one or more limiting growth
factors needed for photosynthesis, such as sunlight, CO2, and nutrient fertilizer, has
been accelerated by human activities (Schindler 2006). Finally, increased acidity in for
example terrestrial systems leads to a rise of disintegration of (essential) minerals.
Although, to some extent the disintegration of minerals can neutralize acidifying
depositions, it also leads to an imbalance of nutrients. More than 95% of the total
acidifying emissions are contributed by releases of nitrogen (e.g. NOx and NH3) and
sulphur (e.g. SO2) to air (EDIP 2003 2005).
76
REFERENCES
1. Fertilizer Regulatory Policies and Implementing Guidelines (1st Ed.) © 2013
Fertilizer Regulatory Division, Fertilizer and Pesticide Authority, Republic of the
Philippines
2. Interim Rules and Regulations Governing the Transmission, Distribution, and Supply
of Natural Gas ©2002 Department of Energy, Republic of the Philippines
3. Mols (2016) Assessment on environmental impacts of biogas production using a Life
Cycle Approach ©2016 Materials and Processes of Sustainable Energetics, Tallinn
University of Technology
4. Stucki, Jungbluth, Leuenberger (2012) Life Cycle Assessment of Biogas Production
from Different Substrates. ©2012 ESU Services Ltd.
5. Schori, Frischknecht (2012) Life Cycle Inventory of Natural Gas Supply ©2012 ESU
Services Ltd.
6. Galamay, Gutierez, Siringan, Tacazon (2017) Methane Production from Municipal
Solid Wastes ©2017 College of Engineering, Cagayan State University, Tuguegarao
City Cagayan
7. Svoboda (1995) Note on Life Cycle Analysis ©1995 Pollution Prevention in Corporate
Strategy, National Pollution Prevention Center for Higher Education, Michigan USA
8. Adviento, Ramirez, Tannagan (2013) Production of Methane gas from Municipal
Solid Waste ©2013 College of Engineering, Cagayan State University, Tuguegarao
City Cagayan
9. Datul, Dizon (2015) Production of Renewable Natural Gas (Biomethane) from Pig
and Chicken Manure ©2015 College of Engineering, Cagayan State University,
Tuguegarao City Cagayan
10. Bingemer, H. G., Crutzen, P. J. (1987). The Production of Methane from Solid
Wastes. Journal of Geophysical Research
11. Jørgensen, P.J. (2009). Biogas – green energy. Aarhus University.
12. Biomethane Regions. Introduction to the Production of Biomethane from Biogas.
13. Monnet, F. (2003). An Introduction to Anaerobic Digestion of Organic Wastes. Final

Report, Scotland.
14. Mes, T.Z.D., Stams, A.J.M., Reith, J.H., Zeeman, G. (2002). Methane production by
anaerobic digestion of wastewater and solid wastes.
77
Upgrading. Ind. Eng. Chem.
16. Forster-Carneir, T., Isaac, R., Pérez, M., Schvartz, C. (2012). Anaerobic Digestion
Pretreatments of Substrates. Biogas Production
17. Fact Sheet, Anaerobic Digestion. (2015). European Bioplastic.
18. Themelis, N.J. (2002). Anaerobic Digestion of Biodegradable Organics in Municipal
Solid Wastes. Columbia University.
19. Uddin, M., Mojumder, S. (2011). Biogas Production from Municipal Waste: Prospect
in Bangladesh. Multidisciplinary Journals in Science and Technology, Journal of
Selected Areas in Renewable and Sustainable Energy.
78
In
Name of Student: ______________________________________________________________
Title of Report: __________________________________________________________
Topic Unacceptable Marginal (1) Acceptable Exceptional

Points
(Weight) (0) (2) (3)
continuity.
79
defined.
Grammar
Weight: 5
Weight: 4
text.
referencing system.
TOTAL
80
APPENDIX
Table 1. Material Balance Summary
Equipment Stream Inflow Outflow

(kg/day) (kg/day)
m1 136,986.3014
Pressure Swing
P1 100,000
Adsorption
P2 36,986.30137
m1 136,986.3014
H2S Scrubber
m2 137931.0345
m3 20,000
m4 20,944.7331
Condenser m2 137931.0345
m5 166,666.6667
m6 28,735.6322
m5 166,666.6667
Anaerobic
Digester m7 1,666,666.667
m8 1,500,000
81
m7 1,666,666.667
Pasteurizer
m9 1,083,333.333
m10 583,333.3337
m10 583,333.3337
Shredder
m11 583,333.3337
m11 583,333.3337
Rotary Drum
Reactor m12 870,646.7667
m13 287,313.433
Total 5,248,897.437 5,248,897.437
82
Table 2. Energy Balance Summary
Equipment Temperature Pressure Description Energy

Name (ºC) (atm) (kW)
Digester 55 0.05 Shredded 2614.753
Biomass
Steam
Heat of 567.88
Reaction
Heat Input
Condenser 25 1 Cooling 166
Water
Biogas
PSA 55 6 Amine 455.494
Solution
Gas
Mixture
Digestate 25 1 Cooling 807.281
Cooler Water
Cooling
Water
TOTAL 4611.408
83
84
Figure 1. Process and Instrumentation Symbology
85
EQUIPMENT DESIGN
1. PRESSURE SWING ADSORPTION COLUMN
2. BIOMETHANE STORAGE TANK
86
3. ROTARY DRUM REACTOR
4. BIODIGESTER
87
5. PUMP
6. SHREDDER
88
7. WATER STORAGE TANK
89
8. MXING TANK
9. GAS SCRUBBER
90
91

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BIOMETHANE PRODUCTION FROM MUNICIPAL ORGANIC WASTE

A PROCESS AND EQUIPMENT DESIGN REPORT

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE

BACHELOR OF SCIENCE IN CHEMICAL ENGINEERING

Engr. CAESAR POBRE LLPITAN

Dear Engr. Llapitan:

We hope that this report will merit your approval.

In Chapter 1, the product information, properties, and demand, alternative designs,

1.1 Product Information

1.2 Product Properties

1.3. Alternative Designs of Biogas Production

Storage for Feeding

Figure 1.1. Biogas Production from Thin Stillage

1.3.3 Gas Separation by Pressure Swing Adsorption

Pressure swing adsorption method involves the adsorption/desorption of

Biogas Pressure Swing Storage Tank

Figure 1.3. Methane Purification by Pressure Swing Adsorption

1.4 Process Selection

The aim of biomethane production is to reduce environmental waste issues and

Natural Gas Consumption

Figure 1.4 Previous Consumption of Natural Gas in the Philippines

1.6 Environmental Issues

13. FNR. (2013). Biogas an introduction. Fachagentur Nachwachsende Rohstoffe e.V.

Name of Student: _____________________________________________________________

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Instructor/Rater: Engr. CAESAR P. LLAPITAN

2.1 Design Objective

2.2 Design Synthesis

The conversion of organic solid waste into methane is undertaken in an anaerobic

2.2.5 Pressure swing adsorption is incorporated in the further purification of methane.

Name of Student: ______________________________________________________________

Title of Report: __________________________________________________________

Topic Unacceptable Marginal Acceptable Exceptional

Instructor/Rater: Engr. CAESAR P. LLAPITAN

Material and Energy Balance

in this chapter are the material and energy balance.

100,000 kg per day of biomethane using organic solid wastes.

Energy balance is based on the law of conservation of energy which helps in

3.1 Material Balance Calculation

3.1.1 Material Balance Around Pressure Swing Adsorption

b. Total CO2 recovery (Air Products and Chemicals Inc.,2010)

c. Daily biomethane production (P1) of 100,000 kg.

Figure 3.1.Material balance around pressure swing adsorption.

Degrees of Freedom Analysis

= 0 degree of freedom (the problem is solvable)

Overall material balance:

m1  136,986.3014 kg H 2 S free biogas

Carbon Dioxide Balance

b. m1  136986.3014 kg H 2 S free biogas

a. H2S composition of biogas is 1%

b. Total removal of H2S

c. Amine solution flow rate (m3) of 20,000 kg per day.

Figure 3.2. Material balance around H2S scrubber.

Degrees of Freedom Analysis

= 0 degree of freedom (the problem is solvable)

Amount of sulphur present in the biogas stream

amount of sulfur  amount of sulfur scrubbed  0.01(m 2 )

Mass fraction of sulphur in the scrubbing solvent

weight sulfur 1379.310345

a. Total removal of water.

Figure 3.3. Material balance around condenser.

Degrees of Freedom Analysis

= 0 degree of freedom (the problem is solvable)

Overall material balance: