m2m cmm tech database

8/6/2019 M2M Cmm Tech Database

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METHANE TECHNOLOGIES FOR MITIGATION AND UTILISATION

Part I - Technologies:

A) Methane CombustionTECHNOLOGY CONTACTS DESCRIPTION

Internal combustion engines suitable for

CMM include: Caterpillar, GE Jenbacher,

Waukesha, Deutz, MAN, plus others

Caterpillar has introduced a larger, more efficient model that is

suitable for CMM, landfill methane, natural gas. The CAT

G3520 Gas Engine produces 1600kW with an efficiency of about

40% and NOx ratings as low as 0.5 g/bhp-hr.Minimum methane concentration for gas engines may be as low

as 25%.

Mitsubishi Heavy Industries Ltd (Power

Systems Headquarters)

http://www.mhi.co.jp

World's highest generation efficiency level gas engines.

Investigating the application of CMM and VAM.

Ishikawajima-Harima Heavy Industries Co

Ltd (Power Plant Division)

http://www.ihi.co.jp

High efficiency gas engines for CMM and VAM

i. Gas Engines

Mitsui Engineering and Ship building Co

Ltd (Power Systems Sales Department)

http://www.mes.co.jp

High efficiency gas engines for CMM and VAM

Several manufacturers make gas turbines

and microturbines to run on VAM: Solar

(division of Caterpillar), ALSTOM Power,General Electric, Turbo Power (United

Technologies), Rolls Royce, Hitachi,

Capstone, Ingersoll-Rand, etc

A wide variety of gas turbines may be fuelled with CMM. For

best results, methane concentration should be maintained above

35% with minimal variability.

ii. Gas Turbines, including

microturbines

Kawasaki Heavy Industries (gas turbine

business centre)

http://khi.co.jp/gasturbine/

High efficiency gas turbine for CMM and VAM

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iii. Co-firing boiler for CMM

and coal

Ishikawajima-Harima Heavy Industries Co

Ltd

(Power Plant Division)

http://www.ihi.co.jp

Co-firing boiler for CMM and coal / low grade coal.

B) Drainage Gas Purification for Pipeline/Town GasTECHNOLOGY CONTACTS DESCRIPTIONThere are six basic processes

that may be used to reject

nitrogen, the major contaminant

for CMM upgrading:

i. Solvent Absorption Advanced Extraction Technology

Tom Gaskin, VP TechnologyT. (281) 447-0571

E-mail:[email protected]://www.aet.com/home.htm

Sometimes referred to as Selective Absorption, this process uses

specific solvents that have different absorption capacities withrespect to different gas species. For CMM, a solvent selectively

absorbs methane while rejecting a nitrogen-rich stream in a

refrigerated environment. The petroleum industry commonly uses

selective absorption to enrich gas streams. AET has no experience

with CMM.

ii. Pressure Swing Adsorption (PSA) Gas Separation Technologies, LLCMajor Seery, President

T. (303) 430-1430

[email protected]

http://www.gassep.com

Northwest Fuel Development, Inc.

In most PSA nitrogen rejection systems, wide-pore carbonmolecular sieves selectively adsorb nitrogen and methane at

different rates in an equilibrium condition. In a CMM stream

containing a mixture of air (nitrogen and oxygen) and methane,

methane is preferentially adsorbed during each pressurization

cycle. The process recycles methane-rich gas so that methane

proportions increase with each cycle. PSA recovers up to 95

percent of available methane and may operate on a continuous

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Peet St, PhD, President

T. (503) 699-9836

[email protected]

http://www.northwestfuel.com

basis with minimal on-site attention. PSA systems have excellent

turndown capability so they are able to operate effectively with

gas flowing at a fraction of rated capacity. Gas Separation

Technologies uses zeolite instead of wide-pore carbon molecular

sieve adsorbents. Neither vendor has built a full-scale facility.

iii. Molecular Gate Engelhard Corporation

Michael Mitariten

Iselin, NJ 08830-0770T. (732) 205-5000

[email protected]

www.engelhard.com

This process removes nitrogen and other contaminants from the

methane, whereas other processes remove the methane from the

nitrogen. For safety reasons, most of the oxygen must be removedupstream of the molecular gate system. The process uses a new

type of molecular sieve that has the unique ability to adjust pore

size openings within an accuracy of 0.1 angstrom. For CMM, the

sieve pore size is set smaller than the molecular diameter of

methane and larger than the molecular diameters or nitrogen,

oxygen, carbon dioxide, and water. This permits the nitrogen and

other contaminants to enter the pore and be adsorbed while

excluding the methane, which passes through the fixed bed of

adsorbent at essentially the same pressure as the feed.

The molecular gate process employs a PSA operation by

swinging the adsorbent bed pressure from a high-pressure feed

step that adsorbs the contaminants to a low-pressure regeneration

step to remove the previously adsorbed contaminants. Engelhard

has installed three full-scale plants operating on methane from

abandoned mines.

iv. Cryogenic Separation BCCK Engineering, Inc.

R. Clark Butts, P.E., President

Greg Hall, Sales Manager

Midland, TX 79705

Tel: (915) 685-6095

Greg Hall: [email protected]

The cryogenic process uses a series of heat exchangers to liquefy

the high-pressure feed gas stream. The mixture is then flashed and

a nitrogen-rich stream vents from a distillation separator, leaving

the methane-rich stream. To avoid the danger of explosion within

the plant, designers locate the deoxygenation system at the plant

inlet. Cryogenic plants have the highest methane recovery rate

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mailto:[email protected]://www.northwestfuel.com/mailto:[email protected]://smtpmail.irgltd.com/exchange/LSchultz/Inbox/Upgrade%20report%20comments.EML/1_multipart_xF8FF_2_report%20draft%20PMF%20edits%2009-08-04.doc/C58EA28C-18C0-4a97-9AF2-036E93DDAFB3/www.engelhard.commailto:[email protected]:[email protected]://smtpmail.irgltd.com/exchange/LSchultz/Inbox/Upgrade%20report%20comments.EML/1_multipart_xF8FF_2_report%20draft%20PMF%20edits%2009-08-04.doc/C58EA28C-18C0-4a97-9AF2-036E93DDAFB3/www.engelhard.commailto:[email protected]://www.northwestfuel.com/mailto:[email protected]


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www.bcck.com

(i.e., about 98 percent) of any of the technologies. Large-scale

cryogenic plants have become a standard and economic solution

for upgrading below-specification gas from natural gas fields, but

they tend to be much less cost-effective at sizes below 5 mmscfd.

BCCK has installed three full-sized plants that upgrade CMM to

pipeline quality gas.

v. Membrane Separation Membrane Technology and Research (with

ABB)

The process uses membranes to selectively pass methane, ethane,

and higher hydrocarbons while retaining nitrogen. A simple one-stage membrane unit would be appropriate for feed gas containing

about 6 to 8 percent nitrogen, but more commonly (where nitrogen

concentrations are higher) a two-stage membrane system would be

required. USEPA has received little information on this

technology.

vi. Centrifugal Separation Bose Research and Development

www.reducingglobalwarming.com

The Bose System's Centrifugal Separation process is based on the

molecular weight difference of the gas species contained in the

CMM/AMM gases recovered. The Bose System has shown gas

separation efficiencies of 70-75% in the automobile exhaust

application.

C) Ventilation Air Methane Mitigation and Utilisation via Thermal Oxidation.TECHNOLOGY CONTACTS DESCRIPTION

i. PF Power Stations Power Coal

(The proposed project to link underground

mines to a power station ceased)

If ventilation air can be delivered to a large fuel consumer, such as

a coal-fired power station boiler, it can readily replace ambient air

for all or part of the combustion air requirements. However, in

general, power stations are not convenient to all gassy mines and

this limits the suitability of this technique.

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ii. Hybrid Waste Coal/Methane

(VAM) Combustion in Kiln

ComEnergy

Phone 61-7-3878 7622

Email [email protected]

www.comenergy.com.au

CSIRO has been developing a coal mine waste methane/coal

utilisation technology, with the aim of not only mitigating mine

methane and waste coal, but to also of recovering energy for

power generation. The VAM/coal mixture burns in a rotary kiln,

and the sensible heat from the products of combustion is captured

in an air-to-air heat exchanger. Clean, pressurized, heated air

expands in a gas turbine, which operates an electric generator.

iii. Hybrid Waste Coal Methane

Combustion in Fluidised

Bed

A proposed concept, no real development

on this yet.

Fluidised beds suspend solid fuels on upward blowing jets of air

during the combustion process. The result is a turbulent mixing of

gas and solids. The tumbling action, much like a bubbling fluid,

provides for high chemical reaction rates and heat transfer.

iv. Thermal Flow Reversal

Reactor (TFRR), also

Flameless Thermal

Oxidation (FTO) and

Regenerative Thermal

Oxidation (RTO)

1. MEGTEC Systems

Richard Mattus

[email protected]

Goteborg, Sweden

T. 46 31 65 7800

http://www.megtec.com

2. Biothermica, Montral, Qubec H2L 1J6

T. 514.488.3881

[email protected]

Ventilation air enters reactor and flows in one direction into a

preheated ceramic bed that increases its temperature to above the

ignition point of methane (i.e., 1,832oF or 1,000oC). Oxidation of

the VAM takes place in the bed, and the hot products of oxidation

continue through the bed, losing heat to the far side of the bed in

the process. When the far side of the bed is sufficiently hot, the

reactor automatically reverses the direction of ventilation airflow

to maintain the thermal environment necessary to continue the

auto-oxidation process in the oxidizer core. The installations of the

flameless and NOx free VOCSIDIZER process from MEGTEChas been demonstrated at four coal mine sites in Europe, Australia

and in the USA. Some MEGTEC demonstrations include energy

recovery.

v. Recuperative lean-burn gas

turbine

EDL. The development ceased. EDL technology is a recuperative gas turbine, which uses heat

from the combustion process to preheat the air containing methane

to the auto-ignition temperature (in the range of 700-1000 degrees

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Celsius), with the combusted gas being used to drive a turbine.

D) Ventilation Air Methane Mitigation and Utilisation via Catalytic OxidationTECHNOLOGY CONTACTS DESCRIPTION

i. Catalytic Monolith Reactor For VAM mitigation purpose

Commonwealth Scientific and Industrial

Research Organization (CSIRO)

Exploration and Mining

www.csiro.com.au

Catalytic monolith reactor technology uses a honeycomb type

monolithic reactor which is a type of reactor in common use due to

its outstanding characteristics of very low pressure drop at high

mass flows, high geometrical area, and high mechanical strength.

Monoliths consist of a structure of parallel channels with walls

coated by a porous support containing catalytically active

particles.

ii. Catalytic lean-burn gasturbines

1. VAMCAT by CSIRO2. Ingersoll-Rand Microturbine

3. FlexEnergy Microturbine

There are several leanburn gas turbines being developed in theworld. These include CSIRO lean-burn catalytic turbine,

Ingersoll-Rand microturbine, and the FlexEnergy Microturbine.

In general, the catalytic turbine intakes a very lean fuel/air

mixture, and compresses it, and combusts it in a catalytic

combustor. The turbine operates at low temperatures, so does not

use combustion air for dilution and internal cooling, thus allowing

the air intake to contain methane.

iii. Catalytic lean-burn gas

turbine

VAMCAT by CSIRO

Dr. Shi Su

[email protected]

CSIRO Exploration and Mining

Queensland Centre for Advanced

Technologies

Technology Court

CSIRO, with the support of the Australian Greenhouse Office and

Chinas Shanghai Jiaotong University and Huainan Coal Mining

Group will construct the first VAMCAT pilot-scale demonstration

unit at a coal mine in China.

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Pullenvale QLD 4069

Australia

iv. Catalytic lean-burn gas

microturbine by Ingersoll-

Rand

Ingersoll-Rand Energy Systems

Davidson, NC, USA

T. 704 896 4358

E-mail: [email protected]

Ingersoll-Rand (IR) has developed a microturbine that will run on

1.0% ventilation air methane (VAM), and as low as 0.86%. It is a

lean-fuel version of PowerWorks Microturbine System. The

current prototype is rated at 70 kW and is designed for remote

outdoor installations.

v. Catalytic lean-burn gas

microturbine by FlexEnergy

Edan Prabhu, President

FlexEnergy

22922 Tiagua

Mission Viejo, CA 92692, USA

T. 949 380-4899

E-Mail: [email protected]

The FlexEnergy Microturbine, adapted from the commercially

available Capstone microturbine, is designed to accept a wide

range of fuels, including VAM. A FlexEnergy unit can achieve

full power with fuel as low as 1.3% methane (~ 13 Btu/ft3)

delivered at atmospheric pressure. Even lower concentrations may

be used, but will not generate full power. The fuel/air mixture iscompressed and then oxidized in a catalytic combustor. The hot

compressed gases expand in the turbine to power the 30 kW

generator. The compressor and combustor are contained within a

compact turbine module.

FlexEnergy is seeking sites for demonstration projects on ultra-

low Btu fuels including VAM. The company intends to develop

the system to run on lower Btu fuels (target 1.0% methaneconcentration). Development of larger units (60 kW and 200 kW)

is under consideration as well.

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vi. Catalytic Flow Reversal

Reactor (CFRR)

CH4MIN System by CANMET

Hristo Sapoundjiev

T. 450 652 5789

Varennes, Quebec, Canada

http://cedrl.mets.nrcan.gc.ca

The CFRR has the same basic design and operation as the TFRR,

except that oxidation takes place in the presence of a catalyst at

temperatures well below the 1000oC needed for the TFRR. As yet

there is no design to use the energy released. The system has been

demonstrated at small scale in the CANMET laboratory.

E) Enriching Dilute MethaneTECHNOLOGY CONTACTS DESCRIPTION

CSIRO and Australian Coal Association

Research Program

Concentrators have been applied to several industries to capture

volatile organic compounds. A concentrator of this type could be

used to enrich methane in mine ventilation air to levels that meet

the requirements of lean-burn methane utilisation technologies,such as catalytic and recuperative gas turbines. This involves

taking the 0.1-0.9 % methane stream and increasing the methane

to a concentration of greater than 20 %.

This technology is currently under development by CSIRO and

ACARP.

i. Concentration

Bose Research and Development Inc

www.reducingglobalwarming.com

A battery of Bose System Gas Turbines (US Patent Pending No.

11/394,576) using compressed VAM from active coal mines canbe shown to centrifugally separate the methane from 0.1 0.9%

VAM to a concentration of greater than 20%, for use in micro

turbines.

ii. Gas upgrading system Gas and Power Investment Co Ltd

(Energy and Business Development

The unit increasing concentration of methane for CMM and VAM

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Department)

http://gasandpower.co.jp

[email protected]

F) Measuring and Monitoring MethaneTECHNOLOGY CONTACTS DESCRIPTION

i. Gas simulation software

(1) MGF 3D

(2) COSFLOW

(3) KAZEMARU

Japan Coal Energy Centre (Resources

Development Department)

http://www.jcoal.or.jp

(1) [email protected]



(1) PC based simulation software for emission and recovery of

coal mine methane developed by JCOAL

(2) Computer simulation software for emission and recovery of

coalmine methane developed by CSIRO and JCOAL

(3) PC based simulation system to analyse mine ventilation

network, developed by JCOAL

ii. Gas contents analysis

apparatus

Japan Coal Energy Centre (Resources

Development Department)

http://www.jcoal.or.jp

[email protected]

Portable and compact gas analysing apparatus to measure gas

contents in coal on site

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Part II - Technology Applications (Methane Utilization Projects):

A) DrillingTECHNOLOGY CONTACTS DESCRIPTION

i. Surface to inseam (coal

seams below the surface)

Wilkie Creek, Xstrata

Newlands, Xstrata

Grasstree, Anglo Coal

Coal seam methane is drained from the virgin seam several years

in advance of mining. Usually vertical holes are drilled

approximately one kilometre a part and directional drilling

technology is used to drill horizontally through the coal seam toconnect the vertical wells. Firstly water is drained from the coal

seam followed by a constant supply of >90% methane.

ii. Surface to inseam (coal

seams exposure in high wall

mining)

Dawson Seamgas

Moura Mine

German Creek

Anglo Coal Australia

Anglo Coal Australia Pty Ltd

Phone +61 7 3834 1333

www.anglocoal.com.au

Coal seam methane is drained from exposed high walls with a

series of horizontal wells into both highwall and underground

seams several years in advance of coal mining. Approximately 3

PJ of coal mine methane per year is supplied from this colliery to

the regional transmission line. A gas processing plant located on

site dehydrates and compresses the gas before delivering it to the

pipeline. Methane concentration is >90%.

iii. Pre drainage (in seam,

underground coal mining)

Appin, BHPB

German Creek, Anglo Coal

Newlands, Xstrata

West cliff, BHPB

In seam drilling involves drilling a series of holes into the coal

seam in a fan formation. These holes, approximately 250 -290

meters long, are drilled from underground roadways as connected

through a drainage pipe network. Methane concentration variesfrom 60-80%.

iv. Post drainage (post

mining/goaf, underground

coal mining)

Appin, BHPB

Dartbrook, Anglo Coal

West Cliff, BHPB

Central Colliery, Anglo Coal

Methane is collected from the goaf following long wall operations.

This results in drainage gas with a concentration of approximately

40-70% methane.

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Note: Conventional technologies, including gas engines, can be used for high concentration drainage gas from the above activities with methane

content greater than 30 percent.

B) Methane CombustionTECHNOLOGY CONTACTS DESCRIPTION

i. Gas Flaring Shell

Central Colliery at the German Creek Coal

Mine, Qld

Shell Coal

Tel 07 3834 1215

www.shell.com.au

http://www.greenhouse.gov.au/challenge/m

embers/success-stories/shell.htm

Note: Central Colliery will closing by the

end of 2006. Shell sold all its Australian

coal interests to Anglo America Corp.

A flaring facility at the Central colliery burns methane converting

it into CO2 and water. In addition to providing immediate

greenhouse gas savings, the flare will complement any future more

productive use of the gas by burning excess gas from other

processes.

ii. Gas Engines Envirogen Pty Ltd

Okay Creek

Tahmoor Colliery

Teralba and Billambi Mines

Energy Developments Ltd (EDL)

German Creek Coal Mine

http://www.greenhouse.gov.au/ggap/

successfulprojects/teralba_northgoonyella.h

tml

Internal combustion gas engine projects that have been installed in

Australia.

Retrofit of the Bose M2M System No.1 for concentrating the 30%

purity CMM to 80% concentration, will result in an estimated I.C.

Engine / Alternator efficiency increase from 18% to 28% giving

significant IRR (ROI) on Bose System Investment costs.

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iii. Fuel Cell FuelCell Energy, Inc.

3 Great Pasture RoadDanbury, CT 06813

DOE Contract DE-FC26-00NT40979

Fuel cell operation is a chemical reaction of fuel in water that

creates an electric potential between two electrodes. The chemicalenergy of the reaction is converted to electricity and heat. A fuel

cell can operate on low-Btu CMM with a methane content of 40%

or higher.

FuelCell Energy (FCE) with support from the U.S. Department of

Energy (DOE) National Energy Technology Laboratory (NETL)

and Northwest Fuel Development demonstrated the use of CMMin a 250kW carbonate Direct FuelCell power plant at a test site

in Hopedale, Ohio, USA.

At current fuel cell costs and electric power rates, subsidies would

be required to make the cost of CMM/fuel cell-based electricity

competitive. FCE is currently engaged in an aggressive cost

reduction program to reduce the plants capital cost. The company

anticipates that future power plants utilizing CMM will producepower at competitive costs.

C) Ventilation Air Methane Mitigation and Utilisation via Thermal Oxidation.TECHNOLOGY CONTACTS DESCRIPTION

i. VAM fuelled Power Plant

by MEGTEC

VOCSIDIZER

BHP Billiton and MEGTEC Systems

Westcliff Colliery

http://www.bhpbilliton.com/bb/

newsCentre/newsAtBhpBillitonDetail.

jsp?id=News/2004/[email protected]

WestVAMP is a large scale demonstration project abating

the VAM of 250 000 Nm3/h (150 000 scfm) of ventilation

air, representing approx 1/5 of the total flow, and generating

high grade steam driving a 6 MWe conventional steam

turbine. The project is partly funded by Australian

Greenhouse Office (AGO).

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Richard Mattus, [email protected] The project, located alongside existing surface facilities at

West Cliff Colliery, is based upon VOCSIDIZERtechnology developed by emission control specialist

MEGTEC System by combining conventional technology in

a new (patented) way, allowing to utilize VAM as fuel for

generating electricity. This system converts low

concentration methane to carbon dioxide (CO2) and water

vapour though an oxidation, or flameless combustion,

process. High efficiency heat exchangers recover the largeamounts of thermal energy released to produce high quality

steam. This steam is used to drive a conventional steam

turbine to generate electricity. MEGTEC has the only

technology that has reached this stage of development.

A VOCSIDIZER system without an electrical power

generation section may be used for generating thermal

energy for heating or cooling, or it can be operated inoxidation-only mode to merely mitigate VAM emissions.

ii. VAM Energy Recovery by

MEGTEC

VOCSIDIZER

BHP Billiton, ACARP and MEGTEC Systems

Appin Colliery

Demonstration of Energy Recovery from VAM by during

12 months in 2001 - 2002 boiling water using only VAM as

fuel for the process. Demonstration was partly funded by

Australian Coal Association Research Program (ACARP),

who in 2005 awarded it as the Best Green House GasProject supported by ACARP.

iii. VAM Abatement in the

US by MEGTEC -

VOCSIDIZER

CONSOL Energy, US Environmental Protection

Agency (EPA), US Department Of Energy (DOE)

and MEGTEC Systems

This large scale installation of 50 000 Nm3/h (30 000 scfm)

is installed on an abandoned mine in West Virginia and is

injecting mine gas of fluctuating concentration into fresh air

in order to simulate VAM, and to demonstrate the efficient

abatement thereof. It also demonstrates obtaining a steady

VAM concentration by injecting CMM into a large air flow.

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iv. Gas Engine Power Station

using Ventilation AirMethane (VAM)

Appin Gas Engine Power Plant

EDL(ventilation air supply ceased due to gas cleaning

economic issue)

Used as combustion air for gas engines to supplement CMM

and natural gas fuel supply. The process has the potential tocontribute up to 10% of a plants fuel supply. The use of

VAM as combustion air in gas turbines is a feasible option

as well.

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