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METHANE RECOVERY FROM ANIMAL MANURES: THE CURRENT OPPORTUNITIES CASEBOOK 1,500 ppm sulfur dioxide. Using dairy manure as the feedstock, this value could be as low as 480 ppm or as high as 2,000 ppm. Given the assumed sulfur dioxide content, the facility contributes 1.67 tons of sulfur dioxide to the atmosphere annually. The second-largest amount of air emissions released by the facility are nitrogen oxides, of which 0.91 tons are discharged every year. Although this and the sulfur dioxide would fall far below the 100 tons/year threshold allowed for an attainment area under the Title V air permitting system, it is recommended that a clarification be made with an appropriate state agency on the exact nature of construction and operating permits that would be required to operate a facility such as this. 3.2.2 Costs and Benefits Estimates The complete digester system consists of three components: an energy plant, a digester plant, and a solids processing plant. As already discussed, the normal efficiency of a small internal combustion engine that converts biogas into electricity is about 24.4%, a heat rate of 14,000 Btu/kWh. The basic cost of this type of engine/generator, including heat recovery and controls, was estimated to be $1,050/kW. The engine/generator is assumed to be housed in a 30 x 30 ft building. A stand-by flare should also be nearby to burn off biogas in the event something prevents it from being combusted in the engine. As already mentioned, the digester was assumed to be a plug-flow reactor, a process developed during the 1970s. Other digestion plant subsystems include a receiving pit that has storage capacity equivalent to 2 days loading rate. Although not factored into this analysis, the digester system should also have a liquid storage tank with enough capacity to hold 6-month’s worth of liquid filtrate. The last component of the digestion system is the solids recovery plant. Each day, a fraction of the digested slurry is discharged and collected in a discharge tank, and fresh feedstock is added to the digester. The collected digestate will be sent to an on-site solids recovery building where mechanical separators divert the fiber and liquid fractions. It was assumed that the project would use a screw-press mechanical separator which is housed in a 20 x 20 ft building. Although the three components of the digestion system are assumed to be “turn key” installed, digester engineering fees and a contingency rider are added to the overall capital cost assumptions. Engineering fees are assumed to be 10% of the entire plant cost. Contingency was also assumed to be 10% of the entire plant cost. The engine and induction generator were estimated to cost $70,284. Including the cost of the flare and other necessary engine plant subsystems, such as the building to house the engine/generator, piping, biogas meters, switchgear, and intertie components required by most electric utilities, the total capital cost for the energy plant was $109,684. The cost of constructing the digester was estimated to be $97,825, including the cost of the cover, as well as all gas handling and transmission costs. The cost of the screw-press separator and building was estimated to be $31,000. Engineering costs and the contingency rider were each estimated to be $23,851. Thus, the total capital expense was estimated to be $286,211. The capital budgeting summary for the dairy manure plug-flow digestion system is provided in Table 3.6. 3-13PDF Image | Methane Recovery from Animal Manures The Current Opportunities Casebook
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