Transcript No Slide Title
Study of the Utilization of Bio-Gas (Methane) for the Coors Brewing Company
By Brian Kish and David Buck
Introduction
The Coors Bottling Plant has been operating in Elkton, VA since 1987
Coors products are brought to the facility by railcars
Then they are blended, finished and packaged
The plant is located between the Blue Ridge Mountains and the South Fork of the Shenandoah River
The plant is designated Class I pristine for Environmental Permitting Conditions
Introduction
Arial picture of the Virginia Facility of the Coors Brewing Company, Shenandoah Bottling Plant.
Expansion at the Coors Plant
Due to the increase in demand for their product Coors is adding another bottle and another can line to their plant in Elkton, VA Competitive Overview of 2000 Increase in Volume of Coors, Miller, and AB
5 4 3 2 1 0 -1 -2 -3 -4 1st Quarter 2nd Quarter YTD Coors Miller A-B
Expansion at the Coors Plant
Expansion will also include upgrades to the wastewater treatment plant.
Such as a
Biogas Boiler Bulk Volume Fermenter Engine Driven Induction Generator Activated Sludge Basin Chlorine Contact Tank
Wastewater Treatment Plant
The Bulk Volume Fermenter
Needs to run at a minimum temperature of 31 o C for maximum efficiency.
In the winter the BVF drops below 31 o C resulting in lower treatment capacity.
Produces methane gas burned as waste.
Previous EPA regulations had prevented Coors from using the excess methane for energy.
The Biogas Boiler
On August 15, 2000, Coors Brewing Company received and amendment to their previous permit allowing the installation of a biogas boiler.
The biogas boiler was specifically approved to burn excess methane gas produced by the anaerobic bacteria in the BVF.
Used to maintain the temperature of the BVF at 31 o C in winter months
A 10 o C drop in temperature will result in a 30-50% reduction in efficiency and treatment capacity.
The Biogas Boiler
Installation of an Induction Generator
The remaining 3.66 million Btu/hr of surplus methane not used by the biogas boiler will be available to one or more induction generators.
The generator will be used to provide electricity for the waste water treatment plant.
Induction Generator
Regulation Involved in the Installation of the Induction Generator
Determining if the induction generator will require a permit.
Size of the generator Fuel type Emissions & emission levels
National Ambient Air Quality Standards (NAAQS)
Emission Rate Exemption Levels Carbon monoxide 100 tons per year Nitrogen dioxide 10 tons per year Sulfur dioxide 10 tons per year Particulate matter (PM10) 10 tons per year 10 tons per year Volatile organic compounds Lead 0.6 tons per year
Determining Emissions Levels from Stack Tests
Stack tests were conducted by Jasper Tech Systems for the following
Hydrocarbons Carbon Monoxide CO Carbon Dioxide CO 2 Oxygen O 2 Nitrogen Oxides NO x
Determining Emissions Levels from Stack Tests
The Pollutants tested in the emissions test were given in percent by volume and part per million (ppm) by volume.
The total exhaust of each pollutant by volume had to be calculated in order to determine the total amount of emissions in tons per year.
This was then multiplied by the density to get the total emissions per year by weight
A single engine had an exhaust rate of 400 ft 3 /min.
Determining Total Engine Exhaust Per Year from the Emissions Test (example calculation)
Total emissions of pollutant per year by volume
= (400 ft 3 /min) (0.1025)(60 min/hr) (8760 hrs/yr)
= 2.155 X 10 7 ft 3 /yr Note: 0.1025 represents the fraction of CO 2 by
Density =
=144 P/R
R= the Universal Gas Constant =1544/MW =1544/44 = 35.09
P = pressure =14.7 psi T = temperature in Rankine = 960 o R
R = 1544/MW = 1544/44 = 35.09
= (144 X 14.7)/(35.09 X 960) = 0.0628 lbs/ft 3
Total emissions of pollutant per year by weight
= (0.0628 lls/ft 3 )(2.155 x 10 7 ft 3 /yr)
= 1.35 x 10 6 lbs/yr
= 677.684 tons/yr
Determining Total Emissions Exhaust from EPA Data
Example Calculation using Sulfur Dioxide SO 2 (725 ft 3 /hr) x (1028 Btu/ft 3 ) / 1000000 = .7453 mmBtu/hr
(0.000588 lb/mmBtu) x (.7453 mmBtu/hr) = 0.000438 lb/hr
(0.000438 lb/hr) x (8760 hr/yr) = 3.839509 lb/yr
(3.839509 lb/yr) / (2000 lb/ton) = .001919 tpy
Final Calculated Emission Rates and Emission Rate Limits for the Induction generator.
Pollutant
Carbon monoxide
Emission Rate Limit (tons/year)
100
Calculated Emissions for a single cogeneration set (tons/year)
27.7427
Calculated Emissions (single) /Limit
3.6046
Calculated Emissions for two cogeneration sets (tons/year)
54.4854
Calculated Emissions (two) /Limit
1.8353
10 14.2187
0.7032
28.4374
0.3516
Nitrogen dioxide Sulfur dioxide 10 0.0019
5263.16
0.0038
2631.5789
Particulate matter (PM10) Volatile organic compounds Lead 10 10 0.6 0.0002517
0.2774
------- 39729.8371
0.0005034
36.0490
------- 0.5548
------- 19864.9186
18.0245
------- Total 100 42.2717
2.3657
84.5434
1.1828
Conclusion
The emission rates for nitrogen dioxide exceed the exemption level listed in 9VAC 5-80-11E. Therefore, the installation of one or more generators would require a permit under 9VAC 5-80-10.
Obtaining a Permit For the Induction Generator
A form 7 is an application for an air permit for new and modified source permits and state operating permits
Acknowledgements
We would like to thank Warren Heidt for the opportunity to complete this project. We would also like to thank him for all of the help and guidance that he gave to us over the last three semesters.
Acknowledgements Cont.
We would also like to thank Dr. Klevickis for all of her help putting this project together. She kept a close eye on us through these past three semesters and made sure that we stayed on the right track.