EPA-600-R-92-007
January 1992
DEMONSTRATION OF FUEL CELLS TO RECOVER
ENERGY FROM LANDFILL GAS
PHASE I FINAL REPORT:
CONCEPTUAL STUDY
by
G. J. Sandelli
International Fuel Cells Corporation
195 Governors Highway
South Windsor, Connecticut 06074
EPA Contract 68-D1-0008
EPA Project Officer. Ronald J. Spiegel
Air and Energy Engineering Research Laboratory
Research Triangle Park, North Carolina 27711
Prepared for
U. S. Environmental Protection Agency
Office of Research and Development
Washington, D.C. 20460
REPRODUCED BY
U.S. DEPARTMENT OF COMMERCE
NATIONAL TECHNICAL
INFORMATION SERVICE
SPRINGRELD, VA 22161
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before complef
1. REPORT NO.
EPA-600-R-92-007
2.
PB92-137520
4. TITLE AND SUBTITLE
Demonstration of Fuel Cells to Recover Energy from
Landfill Gas: Phase I Final Report: Conceptual Study
5. REPORT DATE
January 1992
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
G. J. Sandelli
8. PERFORMING ORGANIZATION REPORT NO.
FCR-11900A
9. PERFORMING ORGANIZATION NAME AND ADDRESS
International Fuel Cells Corporation
195 Governors Highway
South Windsor, Connecticut 06074
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT.NO.
68-Dl-0008
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Air and Energy Engineering Research Laboratory
Research Triangle Park, North Carolina 27711
13. TYPE OF REPORT AND PERIOD COVERED
Phase I Final; 1-9/91
14. SPONSORING AGENCY CODE
EPA/600/13
is. SUPPLEMENTARY NOTESAEERL project officer is Ronald J. Spiegel, Mail Drop 63, 919 /
541-7542.
16. ABSTRACT
The report discusses results of a conceptual design, cost, and evaluation
study of energy recovery from landfill gas using a commercial phosphoric acid fuel
cell power plant. The conceptual design of the fuel cell energy recovery system is
described, and its economic and environmental feasibility is projected. A concep-
tual design of the project demonstration was established from the commercial sys-
tem conceptual design. It addresses the key demonstration issues facing commer-
cialization of the concept. Candidate demonstration sites were evaluated, which led
to selection and EPA approval of the demonstration site. A plan is discussed for
construction and testing of a landfill gas pretreatment system which will render land1
fill gas suitable for use in the fuel cell. The final phase of the study will be!faemon-
stration of the energy recovery concept. -'.-••
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. COSATl Field/Group
Pollution
Fuel Cells
Phosphoric Acids
Energy
Earth Fills
Gases
Pollution Control
Stationary Sources
Energy Recovery
Gas Treatment
13 B
10 B
07B
14G
13 C
07D
8. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
85
20. SECURITY CLASS (This page I
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
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\
t-iiiir |..i I riMr..i,iiKi>Lil Infnnnilioa
IS I I'\Kiv»,n III
l'-:'> \n.h Si
I'V I'M'll
EPA REVIEW NOTICE
This report has been reviewed by the U.S. Environmental Protection Agency, and
approved for publication. Approval does not signify that the contents necessarily
reflect the views and policy of the Agency, nor does mention of trade names or
commercial products constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service. Springfield, Virginia 22161.
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International Fuel Cells FCR-1900A
ABSTRACT
International Fuel Cells Corporation is conducting a U. S. EPA sponsored program to demonstrate
energy recovery from landCll gas using a commercial phosphoric acid fuel cell power plant. The U.S.
EPA is interested in the fuel cell for this application because it is potentially one of the cleanest energy
conversion technologies available. This project report discusses the results of Phase I, a conceptual
design, cost, and evaluation study. The conceptual design of the fuel cell energy recovery system is
described and its economic and environmental feasibility is projected. A conceptual design of the
project demonstration was established from the commercial system conceptual design. It addresses
the key demonstration issues facing commercialization of the concept. Candidate demonstration sites
were evaluated, which led to selection and EPA approval of the demonstration site for this project.
A plan for Phase n activities is discussed. Phase II will include construction and testing of a landfill
gas pretreatment system which will render landfill gas suitable for use in the fuel cell. Phase III will
be demonstration of the energy recovery concept.
in
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International Fuel Cells FCR-11900A
TABLE OF CONTENTS
Section Page
ABSTRACT i 1 i
EXECUTIVE SUMMARY S-l
1.0 INTRODUCTION 1
2.0 CONCEPTUAL DESIGN, COST AND EVALUATION STUDY RESULTS 2
2.1 REQUIREMENT FOR LANDFILL GAS APPLICATION 2
2.1.1 Landfill Gas Availability 2
2.1.2 Landfill Gas Characteristics 3
2.1.3 Emission Requirements 4
2.1.4 Present Options for Methane Abatement from Landfill Gas 4
2.1.5 Requirements for Conceptual Design 4
2.2 COMMERCIAL FUEL CELL LANDFILL GAS TO ENERGY SYSTEM
CONCEPTUAL DESIGN 5
2.2.1 Overall System Description 5
Fuel Pretreatment System 6
Fuel Cell Power Plant 9
Overall System Performance 11
Impact of Heating Value on System Performance 12
2.2.2 Environmental and Economic Assessment on the Fuel Cell Energy
Conversion System 13
Environmental Assessment 14
Economic Assessment Results 15
Comparison With Other Energy Conversion Options 18
Conclusions 19
22.3 Critical Issues 19
Marketing Issues 19
Technical Issues 20
2.3 FUEL CELL LFG-TO-ENERGY SYSTEM DEMONSTRATION 21
2.3.1 Conceptual Design for Demonstrator 21
23.1.1 Overall System and Site Description 22
2.3.1.2 Fuel Cell System Preliminary Design 25
23.1.3 Landfill Gas Pretreatment System Specification and Site
Specific Requirements 27
23.1.4 Gas Pretreatment Conceptual Design 31
23.1.5 Overall Demonstrator Performance 36
23.2 SELECT LANDFILL SITE TO MEET DEMO OBJECTIVES 37
2.3.2.1 Site Selection Criteria 37
23.2.2 Characteristics of Candidate Sites and Selection 38
23.23 Description of Selected Site 40
IV
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International Fuel Cells FCR-11900A
TABLE OF CONTENTS (Cont'd)
Section Page
2.3.3 PHASE n PLAN 44
Task 2.1 Verify Pretreatment System Operation 44
Task 2.2 Demonstration Test Site Specific Design 46
References 48
APPENDDC
A Gas Pretreatment Specification Al
B Gas Analyses From Penrose Landfill Bl
C Gas Pretreatment System Mass and Energy Balance
Preliminary Design Calculations Cl
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International Fuel Cells FCR-11900A
LIST OF FIGURES
Figure Page
S-l. Fuel Cell Energy Recovery Commercial Concept S-l
S-2. IFC's Proposed Demonstrator Concept S-3
2.2-1. Commercial Fuel Cell Landfill Gas to Energy Conversion Concept 5
2^-2. Simplified Block Diagram of Commercial LFG Pretreatment System 6
22-3. Staged Regeneration of Adsorbent Beds and Sample Regeneration Sequence 7
2.2-4. Functional Schematic Fuel Cell Landfill Gas Power Unit 9
2.2-5. Overall System Schematic and Performance Estimate for Fuel Cell
LFG to Energy Conversion System 12
2.2-6. Impact of Landfill Gas Heating Value on Power Plant Power Output
and Heat Rate 13
2,2-7. Comparison of Fuel Cell to Flare for Methane Mitigation
Assuming Electric Revenues. Emission Credits and Thermal Recovery 16
2.2-8. Comparison of Fuel Cell to Flare for Methane Mitigation Assuming Electric
Revenues and Emission Credits 17
2.2-9. Comparison of Fuel Cell to Flare for Methane Mitigation Assuming Electric
Revenues Only 17
2.2-10. Comparison of Fuel Cell to I.C.E. Energy Conversion System 18
23-1. LFG Fuel Cell Demonstration Program 23
2.3-2. Demonstration Project Processes 23
23-3. Photograph of the PC25 Prototype Power Plant 25
23-4. Fuel Processor Life vs. Landfill HaJide Level 27
23-5. Commercial Landfill Gas Cleanup in Rhode Island 31
23-6. Demonstrator LFG Pretreatment System 33
23-7. Overall Performance Estimate for Demonstrator Fuel Cell Landfill Gas
To Energy Conversion System (1 Year Demonstration) 37
23-8. Penrose Plant Supplies Alternative Energy to Southern California Power Grid 41
23-9. Landfill Gas to Electric Power 42
23-10. Fuel Cell Site Options 43
23-11. Phase n Program Logic 44
23-12. Task 2.1 Major Milestone Schedule 45
23-13. Task 2.2 Major Milestone Schedule 47
VI
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International Fuel Cells FCR-11900A
LIST OF TABLES
Table Page
2.1-1. Size Distribution of Landfills and Potential Power Output 2
2.1-2. Landfill Gas Characteristics 3
2.2-1. Key Features of Commercial Pretreatment System Conceptual Design 8
2.2-2. Gas Pretreatment System Projected Performance 8
12-3. Performance Comparison for Nominal 200 kW Output 10
2.2-4. Estimated Fuel Cell Air Emissions 11
2,2-5. Site Characteristics for Landfill Gas Assessment 14
2.2-6. Emissions Impact of Fuel Cell Energy Recovery from Landfill Gas 14
2.3-1. Overall Demonstration Phase I Objectives 21
2.3-2. Conceptual Design Demonstrator Objectives 22
13-3. Improvements to PC25 Landfill Gas Power Plant 26
13-4. Output Gas Requirements to Fuel Cell Power Plant 28
13-5. List of Permits for Penrose Site 29
13-6. Range of LFG Constituents at Penrose 30
2.3-7. Pretreatment System Modifications 32
2.3-8. Pacific Energy Landfill Gas Sites 38
13-9. Assessment of Candidate Sites vs. Evaluation Criteria 39
13-10. Supplemental Landfill Data for Candidate Sites 40
VII
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International Fuel Cells
FCR-11900A
800-KW FUEL CELL POWER PLANT
OPERATING ON LANDFILL GAS
LANDFILL GAS WELLS
AND COLLECTION
SYSTEM
TRANSFORMER
UTILITY
GRID
• V • * 7
LANDFILL SITE
OFFICE AND
BLOWER
MULTIPLE
FUEL CELL
POWER PLANTS
CAS PRETREATMENT
SYSTEM
W-IMt-M
M27M
Figure S-2. Fuel Cell Energy Recovery Commercial Concept
EXECUTIVE SUMMARY
The U.S. Environmental Protection Agency (EPA) has proposed standards and guidelines^1) for the
control of air emissions from municipal solid waste landfills. Although not directly controlled under
the proposal, the emission guidelines would result in the collection and disposal of waste methane,
a significant contributor to the greenhouse effect. This EPA action will provide an opportunity for
energy recovery from the waste methane that could further benefit the environment. Energy produced
from landfill gas could offset the use of foreign oil, and air emissions affecting global warming, acid
rain and other health and environmental issues.
International Fuel Cells Corporation (IFC) was awarded a contract by the U.S. EPA to demonstrate
energy recovery from landfill gas using a commercial phosphoric acid fuel cell. LFC is conducting
a three-phase program to show that fuel cell energy recovery is economically and environmentally fea-
sible in commercial operation. This report covers the results of Phase I, a conceptual design. COSL
and evaluation study, which addressed the problems associated with landfill gas as the feedback for
fuel cell operation.
S-l
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International Fuel Cells FCR-11900A
Phase n of the program includes construction and testing of the landfill gas pretreatment module to
be used in the demonstration. Its objective will be to determine the effectiveness of the pretreatment
system design to remove critical fuel cell catalyst poisons such as sulfur and halides. A challenge test
is planned to show the feasibility of using the pretreatment process at any landfill in conjunction with
the fuel cell energy recovery concept. A preliminary description of the gas pretreater is presented here.
Phase HI of this program will be demonstration of the fuel cell energy recovery concept. The demon-
strator will operate at Penrose Station, an existing landfill gas-to-energy facility owned by Pacific Ener-
gy in Sun Valley, California. Penrose Station is an 8.9 MW internal combustion engine facility supplied
with landfill gas from four landfills. The electricity produced by the demonstration will be sold to
the electric utility grid.
Phase n activities began in September 1991, and Phase HI activities are scheduled to begin in January
1993.
Fuel Cell Energy Recovery Concept
During Phase I, a commercial fuel cell energy recovery system concept was designed. The system,
shown in Figure S-l is based on commercially available equipment adapted for operation on landfill
gas. The system was sized to be broadly applicable to a large number of landfills.
Landfill gas is collected by a series of wells in the municipal solid waste landfill and piped to a gas
pretreatment module. The pretreatment module removes contaminants such as sulfur and halides
which affect the operation of the fuel cells. The contaminants are concentrated on absorption beds
to a predetermined level. Then during a regeneration cycle they are stripped from the absorption me-
dia and destroyed by incineration. Hydrocarbon condensates which form in the pretreater are also
incinerated. The resulting output is a medium Btu methane fuel suitable for use in the fuel cell.
The concept utilizes four modular 200-kW phosphoric acid fuel cells generating electricity to be sold
to the electric utility grid. The fuel cell power plants are adaptations from the natural gas fueled PC25
fuel cell sold by ONSI Corporation, an IFC subsidiary. Only simple modifications are required to
ensure that rated power is achieved from the dilute landfill gas.
Issues to be Resolved
To demonstrate that fuel cell energy recovery is economically and environmentally feasible, two key
issues must be addressed. They are 1) to define a gas pretreatment system to render the landfill gas
suitable for fuel cell use, and 2) to design the modifications necessary to ensure rated power is achieved
from the dilute methane fuel.
The conceptual design of the future commercial system was used as the basis of our evaluation of the
above issues. Requirements for the landfill site, the gas pretreatment system and the fuel cell power
plant were established. These requirements were used by IFC to define demonstration site selection
criteria, and pretreatment module and fuel cell power plant designs. With this level of definition, IFC
was able to extract the demonstration project site-specific conceptual design shown in Figure S-2.
The site selected for the demonstration project during Phase I is the Penrose Station in Sun Valley,
California. This site owned and operated by Pacific Energy, accepts landfill gas from four municipal
solid waste landfills. Penrose Station presently produces 8.9 MW of electricity from landfill gas, using
internal combustion engines. The demonstration will operate on a slip stream from Penrose's gas feed.
S-2
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International Fuel Cells
FCR-11900A
DEMONSTRATION PROJECT CONCEPTUAL DESIGN
I
PENROSE
STATION
GAS WELLS
AND
COLLECTION
SYSTEM
(PACIFIC ENERGY)
UTILITY
POWER
LINES
GAS-GUARD •
GAS PRETREAT-
MENT SYSTEM
(BIOGAS
DEVELOPMENT
INC.)
PC25
FUEL CELL
POWER
PLANT
(ONSI CORP.)
AC POWER i
TO GRID
LANDFILL
COGENERATION
HEAT
NATURAL GAS
SOUTHERN CALIFORNIA GAS COMPANY
RM27M
Figure S-2. IFC's Proposed Demonstrator Concept
Because Penrose accepts gas from four fills, some of which contain industrial waste, the composition
and contaminant levels vaiy considerably. Average methane content is 44 percent and the gas typically
contains 150 ppmv sulfur and 78 to 95 ppmv halides. The sulfur contaminant levels are higher than
typically found in municipal solid waste landfill gas. A successful demonstration at Penrose will show
broad applicability of the concept to the market.
Gas analyses from Penrose were used to guide the design of the gas pretreatment system by Bio-Gas
Development Inc. The Bio-Gas system utilizes a combination of condensate removal by refrigeration
and regenerable absorption beds to clean the gas to meet the fuel cell requirement. Our plan for Phase
n is to construct and test the demonstration pretreater at Penrose prior to siting the fuel cell. This
design verification test is intended to ensure a successful demonstration in Phase TIT,
IFC's evaluation study defined a set of modifications to the natural gas fueled PC25 which could be
easily accomplished in the field. Southern California Gas Co.. long active in on-site fuel cell develop-
ment, will operate the fuel cell during the demonstration and do the in-field modifications.
IFC plans to closely monitor the demonstrator performance test, generating emissions data, landfill
gas quality data, fuel cell performance (electrical and thermal) and system costs. These data will be
evaluated to show the effectiveness of our concept in commercial application. To ensure high quality
data, we plan to conduct a coordinated quality assurance program which will oversee the generation
of measurement data.
Conclusions
The approach used to establish the conceptual design of the demonstration project enabled IFC to
focus on the key issues to be resolved by the demonstration. Our commercial concept generated a
set of requirements which translate directly to demonstrator requirements and are easily verifiable.
We have selected a site which we feel is representative, and which will demonstrate the applicability
of the concept throughout the market. Gas analyses from Penrose enabled Bio-Gas to anticipate the
S-3
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International Fuel Cells FCR-11900A
incoming gas quality and design equipment to meet the challenge. The Bio-Gas design also has built-
in flexibility to accommodate upsets in the contaminant level that may result from weather or natural
phenomenon, thus providing added confidence in the concept. We feel confident the gas pretreatment
system design will produce a quality fuel cell fuel.
The fuel cell modifications required to achieve 200 kW on landfill gas have been identified. Two op-
tions will be provided to EPA for the demonstration fuel cell. These changes are simple and require
only re-engineering. A list of necessary changes at minimum cost will provide a 140 kW rating. Addi-
tional changes which can be accomplished in the field at additional cost to the program will yield 175
kW. The complete list of changes, which would require some engineering and needs to be incorporated
at the time of manufacture, will provide the full 200 kW power rating required in the commercial con-
cept.
We believe we have a demonstration project conceptual design which addresses all the key issues fac-
ing commercial application of the concept. In the next phase, we plan to verify the ability of the gas
pretreatment equipment to yield a quality fuel. We will also prepare a site-specific detailed design
for the demonstration. This design will address not only hardware detail, but also test plans and an
updated demonstration cost estimate.
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International Fuel Cells FCR-11900A
1.0 INTRODUCTION
This report summarizes the work performed under Phase I of U.S. Environmental Protection Agency
Contract 68-D1-0008, "Demonstration of Fuel Cells to Recover Energy from Landfill Gas." This work
was initiated in January 1991 and establishes the conceptual design of a fuel cell energy recovery con-
cept and the site specific demonstration hardware. The Phase I study addressed the problems asso-
ciated with landfill gas as the feed stock for fuel cell operation.
The commercial concept of the fuel cell energy recovery system is based on commercially available
equipment adapted for operation on landfill gas. The first major effort of Phase I was a power system
study which reviewed the competitive requirements for the commercial concept, produced the concep-
tual design, and defined the technology development requirements. This effort is discussed in Sections
2.1 and 2.2 of the report.
A conceptual design of the fuel cell energy recovery demonstrator was extracted from the commercial
concept. The demonstrator addresses the two major technical issues impeding commercialization
of the concept: decontamination of the landfill gas; and power plant power rating on the dilute-me-
thane fuel. This design is discussed in Section 2.3 together with our conclusion from the evaluation
study.
In Phase n of the program we plan to construct and test the gas pretreatment module to be used in
the demonstration. Our objective will be to determine the effectiveness of the pretreatment system
design to remove critical fuel cell catalyst poisons such as sulfur and halides. We plan to conduct a
challenge test to show the feasibility of using the pretreatment process at any landfill in conjunction
with the fuel cell energy recovery concept. A detailed description of the gas pretreater as well as the
site-specific detailed design for the Phase HI demonstration will be documented at the end of Phase
n. The details of our plan are presented in Section 23.3.
The third major effort of this program will be the demonstration of the fuel cell energy recovery con-
cept in Phase HI. The demonstrator will operate at an existing landfill gas energy recovery facility
owned by Pacific Energy in Sun Valley California. The Penrose Station is an 8.9 MW internal combus-
tion engine facility supplied with landfill gas from four separate landfills. The electricity produced
will be sold to the electric utility grid. Site specific data and site requirements are discussed in Section
2.3 of this report.
IFC plans to begin Phase H activities in September 1991 with the approval of the EPA. Phase HI activi-
ties are scheduled to begin in January 1993.
-1-
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International Fuel Cells
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2.0 CONCEPTUAL DESIGN, COST AND EVALUATION STUDY RESULTS
2.1 REQUIREMENT FOR LANDFILL GAS APPLICATION
This section reviews the opportunities for using fuel cells for methane mitigation and energy conver-
sion. A list of requirements was developed for the conceptual design of a commercial fuel cell landfill
gas to energy system. The results of an evaluation study form the basis for a conceptual design of a
demonstrator fuel cell system for testing at a selected landfill gas site.
2.1.1 Landfill Gas Availability
The Municipal Solid Waste (MSW) landfills in the United States were evaluated to determine the po-
tential power output which could be derived using a commercial 200-kW fuel cell. Each fuel cell would
consume 100.000 SCFD* of landfill gas to generate 200 kW. assuming a heating value of 500 Btu per
cubic foot."
The potential power generation market available for fuel cell energy recovery was evaluated using an
EPA estimate of methane emissions in the year 1997<2> and an estimate of landfill gas production rate
of 0.1 SCF/yr per ton"** of refuse in place/3) An estimated 4370 MW of power could be generated
from the 7480 existing and closed sites identified as shown in Table 2.1-1. The largest number of poten-
tial sites greater than 200 kW occurs in the 400 to 1000 kW range. This segment represents a market of
1700 sites or 1010 MW.
The assessment concluded that these sites are ideally suited to the fuel cell concept. The concept can
provide a generating capacity tailored to the site because of the modular nature of the commercial fuel
cell. Sites in this range are also less well served by competing options, especially Rankine and Brayton
Cycles which exhibit poorer emission characteristics at these power ratings.
The result of our assessment is a requirement for the conceptual design of the commercial concept to
be modular in nature and sized to have the broadest impact on the market.
Table 2.1-1. Size Distribution of Landfills
and Potential Power Output
Site Power Rating (kW)
Less than 200
201-400
401-1000
1001-1500
1501-2000
2001-2500
2501-3000
>3000
Total
No. of Sites
3700
1100
1700
380
220
90
60
230
7480 Sites
Total Power
Output (MW)
220
330
1010
480
380
190
160
1600
4370 MW
(•) 1SCFD = 0.028 SCMD
(••) IBtu/ft3 - 373 kJ/m3
(•••) 1 ton - 2000 Ib - 908 kg
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International Fuel Cells
FCR-11900A
2.12 Landfill Gas Characteristics
The available information on landfill gas compositions was evaluated to determine the range of gas
characteristics which a fuel cell landfill-gas-to-energy power plant will encounter. This information
was used to set the requirements for the gas pretreatment and fuel cell power plant designed to operate
on a wide range of available landfill gas compositions within the United States.
A summary of landfill gas characteristics is shown in Table 2.1-2. The heating value of the landfill gas
varies from 350 to 600 Btu per cubic foot, with a typical value of 500 Btu per cubic foot. The major
non-methane constituent of landfill gas is carbon dioxide. The carbon dioxide ranges from 40 to 55
percent of the gas composition on a dry basis. Other diluent gases include nitrogen and oxygen, which
are indicative of air incursion into the well (most frequently in perimeter wells). Nitrogen concentra-
tions can range as high as 15 percent on a dry basis but typical values are five percent or less. Oxygen
concentrations are monitored closely and held low for safety reasons. Pacific Energy has indicated
that the landfill gas is typically saturated with water vapor at temperatures up to L20°F."
Table 2.1-2. Landfill Gas Characteristics
Characteristic
Heating Value
(HHV)
CH4
C02
N2
02
Sulfur as H2S
Halides
Non-Methane Organic
Compounds (NMOCs)
Range
350-600
(Btu/ft3)
35-58%
40-55%
0-15%^)
0-2.5%(1>
1-700 ppmv
N/A
237-14,294 ppmv
Typical
500
(Btu/ft3)
50%
45%
5%
< \% (for safety)
21 ppmv
132 ppmv
2700 ppmv
Note: (1) Highest values occur in perimeter wells
Landfill gas contains trace amounts of nonmethane organic compounds (NMOCs). A typical value of
NMOC concentration of 2700 ppmv (expressed as hexane) was derived from data provided by EPA<4>.
The NMOC concentration in the landfill gas is an important measure of the total capacity required in
the gas pretreatment system, while the specific individual analyses provide a basis for gas pretreat-
ment subcomponent sizing. The specific contaminants in the landfill gas, of interest to the fuel cell, are
sulfur and halides (chiefly chlorides and fluorides). The sulfur level ranges from 1 to 700 ppmv, with a
typical value on the order of 21 ppmv. Sufficient data were not available to assess the range of the
halides, but a typical value of 132 ppmv was calculated for this contaminant**). The range of contami-
nant values varies not only from site to site, but also at any given site with time due to seasonal weather
or moisture content. These characteristics require the pretreatment system design to be capable of
handling these gas quality variations to avoid expensive site specific engineering of the pretreatment
design which would affect the marketability and economics of the concept.
(•) °C - 5/9 (°F-32)
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International Fuel Cells FCR-11900A
2.1.3 Emission Requirements
Existing U.S. regulations do not address methane emissions from landfills directly. Proposed new
EPA regulations^1) would control non-methane organic compounds from large landfills (150 Mg per
year and up) and hence would indirectly control methane emissions.
Landfill gas emission requirements are primarily determined at the state and local level. State require-
ments are generally limited to controlling explosion hazards, typically limiting methane concentrations
to below 25 percent of the lower explosion limit. An evaluation of state regulations revealed that collec-
tion and control requirements generally necessitate venting, or the use of a flare. However, Federal
Clean Air Act requirements are driving the state and local air quality rules toward tighter controls,
including secondary air emissions which would result from energy recovery processes. For instance, in
non-attainment regions for ozone, strict requirements for secondary emissions including NO* carbon
monoxide, and NMOCs may exist. The best known example of such strict local emission requirements
is the South Coast Air Quality Management District (SCAQMD) in southern California.
2.1.4 Present Options for Methane Abatement from Landfill Gas
A number of landfill gas methane abatement options exist, each with its own particular characteristics
and range of applicable economic landfill sizes or site characteristic for optimum use. Among these
options the fuel cell is unique in that it produces electric power and recovers waste heat at higher effi-
ciency and produces negligible secondary emissions. The fuel cell performance allows it to be used
efficiently in small sites, while its modularity allows its use in larger sites covering a significant portion
of the landfill gas market. The characteristic of modularity allows the fuel cell to match the landfill gas
output of the site as production expands or is depleted. A review of the abatement options indicates
that the fuel cell should be evaluated and compared competitively for small (< 1MW) to medium (< 3
MW) capacity sites with the most common means of mitigating methane, the flare, and the lean-burn
internal combustion engine. The internal combustion engine can be modified for cogeneration and/or
secondary emission reduction with the addition of selective catalytic reduction (SCR) with ammonia
and gas pretreatment to protect the emission catalyst from the contaminants in landfill gas. The fuel
cell system was not compared to turbine technologies in this study because the characteristics of the
fuel cell system are attractive to smaller sites and thus the economics cannot be fairly compared. Com-
bustion turbines, however, are an effective abatement option for larger capacity sites (> 3 MW).
2.1.5 Requirements for Conceptual Design
A competitive fuel cell system for abating landfill gas methane can provide an attractive, low emission,
flexible and cost effective alternative to present mitigation and energy conversion systems.
The conceptual design of a landfill gas fuel cell conversion system must incorporate those features
which can provide this capability and be verified in a demonstration program. To meet this potential
the conceptual design must incorporate those features which meet the following requirements:
• Application to a Large Number of Landfills - The conceptual design can accommodate a
wide range of landfill sizes through the use of a basic building block or modularity and
multiples of these modules.
• Accommodation to Variations in Landfill Gas Composition and Contaminant Level - The land-
fill gas pretreatment and fuel cell system is tolerant to variations in gas heating value and
a wide range of contaminant compositions.
• Competitive Economics - Cost to mitigate methane and NMOC emissions from MS W land-
fills to proposed EPA regulations should be minimized.
• Low Emissions - The overall system air emissions, solid and liquid wastes are kept at a
minimum.
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International Fuel Cells
FCR-11900A
2.2 COMMERCIAL FUEL CELL LANDFILL GAS TO ENERGY SYSTEM CONCEPTUAL
DESIGN
This section describes the commercial fuel cell landfill gas to energy system conceptual design. The
conceptual design is based on providing a modular, packaged, energy conversion system which can
operate on landfill gases with a wide range of compositions as typically found in the United States. The
complete system incorporates the landfill gas collection system, a fuel gas pretreatment system and a
fuel cell energy conversion system. In the fuel gas pretreatment section, the raw landfill gas is treated to
remove contaminants to a level suitable for the fuel cell energy conversion system. The fuel cell energy
conversion system converts the treated gas to electricity and useful heat.
Landfill gas collection systems are presently in use in over 100 MSW landfills in the United States.
These systems have been proven effective for the collection of landfill gas. Therefore these design and
evaluation studies were focused on the energy conversion concept.
2.2.1 Overall System Description
The commercial landfill gas to energy conversion system is illustrated in Figure 2.2-1. The fuel pre-
treatment system has provisions for handling a wide range of gas contaminants. Multiple pretreat-
ment modules can be used to accommodate a wide range of landfill sizes. The wells and collection
system collect the raw landfill gas and deliver it at approximately ambient pressure to the gas pretreat-
ment system. In the gas pretreatment system the gas is treated to remove NMOCs including halogen
and sulfur compounds. The pretreatment system design is based upon a commercial system design
operating at a landfill site in Johnston, R.I. The system designed for this program has been modified to
reflect the knowledge gained at that site.
Landfill gas wells
and collection
system
Utility
grid
\
Landfill site
office and
blower
Gas
pretreatment
system
Multiple
fuel cell
power plants
FC307440
RMIMf
Figure 2.2-1. Commercial Fuel Cell LandjUl-Gas-to-Energy Conversion Concept
The commercial energy conversion system shown in Figure 2.2-1 consists of four fuel cell power plants.
These power plants are designed to provide 200 kW output when operating on landfill gas with a heat-
ing value of 500 Btu per standard cubic foot and for accommodating higher contaminant concentra-
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FCR-11900A
tions. The output from the fuel cell is utility grade ac electric power. It can be transformed and put into
the electric grid, used directly at nearby facilities, or used at the landfill itself. The power plants are
capable of recovering cogeneration heat for nearby use or rejecting it to air.
As configured in Figure 2.2-1, the commercial system can process approximately 18,000 standard cu-
bic feet per hour of landfill gas (mitigate 9050 SCFH.of methane) with minimum environmental impact
in terms of liquids, solids, or air pollution. Details of the individual sub-elements in the energy conver-
sion system follow this discussion.
Fuel Pretreatment System
A block diagram of the landfill gas pretreatment system is shown in Figure 2.2-2. The fuel pretreat-
ment system incorporates two stages of refrigeration combined with three regenerable adsorbent
steps. The use of staged refrigeration provides tolerance to varying landfill gas constituents. The first
stage reduces the water content to a uniform dew point of approximately 33°F, and removes some
heavier hydrocarbons from the landfill gas. This concept is based on Bio Gas Development landfill gas
condensate removal composition data and experience at similar operating conditions. The first stage
provides flexibility to accommodate the varying landfill characteristics by delivering a low dew point
gas with a relatively narrow cut of hydrocarbons for the downstream beds in the pretreatment system.
A regenerable molecular sieve bed next reduces the dew point from 33°F to less than -50°F, to prevent
freezing in the second refrigeration step. The second refrigeration step removes additional hydrocar-
bons and enhances the effectiveness of the activated carbon and molecular sieve beds, which remove
the remaining volatile organic compounds and hydrogen sulfide in the landfill gas. This approach is
more flexible than utilizing dry bed adsorbents alone and has built-in flexibility for the wide range of
contaminant concentrations which can exist from site to site and even within the single site varying
with time.
REGENERATION OAS
Figure 2.2-2. Simplified Block Diagram of Commercial LFG Pretreatment System
The three adsorbent beds are regenerated by using cleaned, heated gas from the process stream. Each
adsorbent step consists of two beds in parallel. In operation, one bed is adsorbing while the parallel
bed is being regenerated. The regeneration path and sequence are shown as dashed lines in Figure
22-2. A small portion of the treated landfill gas (approximately 8%) is heated by regeneration with the
incinerator gases and then passed through the beds in the sequence shown. Figure 2.2-3 with its ac-
companying sample regeneration sequence shows the regeneration process in more detail. This sys-
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FCR-11900A
tern provides flexibility in the tailoring of the regeneration of each bed. The exact sequencing, regener-
ation gas flow, and timing would be based on experience gained in the Phase n and HI demonstrations
and final design (bed sizing and material optimizations) of the adsorbent beds for commercial applica-
tions. After exiting the final bed, the regeneration gas is fed into the low NOX incinerator where it is
combined with the vaporized condensates from the refrigeration processes and the mixture is com-
busted to provide greater than 98 percent destruction of the NMOC's from the raw landfill gas. The
exhaust from the incinerator is essentially C&i and water. The pretreatment system design provides
treated gas to the fuel power plant in an efficient, economic, and environmentally acceptable manner.
Bypass
Bypass
Regen
L _
Regen
gas
heater
Bypass for
cooling
j
r
r*
Dehydration
mol
sieve
1
1
1
1
X
Activated
carbon
1
1
Ii
H2S
removal
mol sieve
F
c
To
flare
C32O2 Q
in*na
Staged Regeneration of Adsorbent Beds
8 Hour Sequencing
Step
1
2
3
4
5
6
7
Duration
(hrs)
0.5
1.5
0.5
1.5
2.0
1.0
1.0
Mode
Heating
Heating
Heating
Heating
Cooling
Cooling
Cooling
Regen gas
heater
On
On
On
On
Bypass
Bypass
Bypass
Dehydration
bed
Bypass
Regen
Bypass
Bypass
Regen
Bypass
Bypass
Activated
carbon bed
I Regen |
^^^
Regen
Regen
Bypass
Regen |
| Regen ]
Bypass
H2S removal
bed
Regen
Regen
Regen |
Regen |
Regen |
Regen |
Regen |
FC3243*
910*08 EJ
Figure 2.2-3. Staged Regeneration of Adsorbent Beds and Sample Regeneration Sequence
Key features of the design and the related product benefits are summarized in Table 2.2-1. The system
design provides flexibility for operation on a wide range of landfill gas compositions, and has minimal
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solid wastes, high thermal efficiency and low parasite power requirements. While the pretreatment
system is based upon modification of an existing system and it utilizes commercially available compo-
nents, the process train and operating characteristics of this design need to be validated by demonstra-
tion. Key demonstrations required include: the achievement of the low total halide contaminant levels
in the treated gas; effectiveness of the regeneration cycle as affected by regeneration time and tempera-
ture; durability of the regenerable beds; and low environmental emissions.
Table 2.2-1. Key Features of Commercial Pretreatment System Conceptual Design
Design Feature
Product Benefit
7 psig nominal operating pressure
Two refrigeration stages
Vaporization and incineration of liquid con-
densates from refrigeration stages
All dry beds regenerable
Beds regenerated with heated clean fuel fol-
lowed by low NO, incineration
Recover heat from incineration for vapor-
ization of refrigeration condensate and
heating clean regeneration gas
Low pumping power
Handle wide range of landfill gases
Improve effectiveness of regenerable beds
No contaminated liquid effluents for dis-
posal
Minimal solid waste disposal
No contaminated liquid effluent
High thermal efficiency
The pretreatment system was analyzed to estimate the overall thermal efficiency, the internal electric
power requirements, and its maintenance characteristics. These characteristics are summarized in
Table 22-2. The estimated thermal efficiency is 92 percent with the balance of the thermal energy used
for regeneration, vaporization of condensates and incineration of the regeneration gases. Electric
power is used for pumping the gases and the refrigeration and is accounted for as a parasite power
characteristic of the system. Maintenance requirements consist of maintaining and adjusting controls
and valves in the regeneration system replacement of filter elements, and replacement of fully regener-
ated spent bed materials on an annual basis. The maintenance cost for the system is estimated to be
0.2c/kWhr.
Table 2.2-2. Gas Pretreatment System Projected Performance
Fuel pretreatment system efficiency (% of
raw landfill gas delivered to fuel cell)
Parasite power requirement (% of fuel cell
electric power)
Maintenance Cost
92%
2%
-0.2 c/kWh
The environmental impact of the gas treatment system was evaluated. The impact of air emissions,
liquids, and solids disposal were considered. The incinerator is designed for greater than 98 percent
destruction of all NMOC's, and NO* emissions of less than 0.06 pounds per million Btu* of fuel con-
sumed are expected. There is no liquid effluent from the system since all condensates are vaporized
and subsequently incinerated. Solid disposal involves removing spent regenerable bed materials at the
(•) 1 lb/106 or million Btu - 0.43 kg/106 or million kJ
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factory and treatment by an EPA approved processor for reclamation. The bed materials are routinely
handled and processed by qualified waste processors.
Fuel Cell Power Plant
The commercial landfill gas energy conversion conceptual design incorporates four 200-kW fuel cell
power units. Since each of the four units in the concept is identical, this discussion will focus on the
design issues for a single 200-kW power unit.
A simplified functional schematic of the fuel cell power unit is shown in Figure 2.2-4. Major sections of
the system include the fuel processing system, fuel cell electrical conversion system and the thermal
management system. In the fuel processing section treated landfill gas is converted to hydrogen and
CO2 for introduction into the fuel cell stack. The fuel treatment process includes a low temperature
fuel preprocessor to remove the residual contaminants from the treated gas, a fuel reformer, and a low
temperature shift converter where the exhaust from the reformer is further processed to provide addi-
tional hydrogen and CO2-
FUEL
PROCESSING
SYSTEM
LOW TEMP
FUEL
PRE-
PROCESSOR
ANCILLARY
COOLANT
LOOP
THERMAL-
MANAGEMENT
SYSTEM
Figure 2.2-4. Functional Schematic Fuel Cell Landfill Gas Power Unit
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FCR-11900A
In the fuel cell stacks hydrogen from the process fuel stream is combined electrochemically with oxy-
gen from the air to produce dc electricity and byproduct water. The product water is recovered and
used in the reformer. The heat generated in the cell stack is removed to an external heat rejection
system. This energy can be either rejected to the ambient air or recovered for use by the customer. The
dc power produced in a fuel cell stack is converted to ac power in a power conditioning package not
shown on the process schematic.
A preliminary design of a fuel cell power plant was established to identify the design requirements
which allow optimum operation on landfill gas. Three issues specific to landfill gas operation were
identified which reflect a departure from a design optimized for operation on natural gas. A primary
issue is to protect the fuel cell from sulfur and halide compounds not scrubbed from the gas in the fuel
pretrealment system. An absorbent bed was incorporated into the fuel cell fuel preprocessor design
which contains both sulfur and halide absorbent catalysts. A second issue is to provide mechanical
components in the reactant gas supply systems to accommodate the larger flow rates that result from
use of dilute methane fuel. The third issue is an increase in the heat rate of the power plant by approxi-
mately 10 percent above that anticipated from operation on natural gas. This is a result of the ineffi-
ciency of using the dilute methane fuel. The inefficiency results in an increase in heat recoverable from
the power plant. Because the effective fuel cost is relatively low, this decrease in power plant efficiency
will not have a significant impact on the overall power plant economics.
The landfill gas power plant design provides a packaged, truck transportable, self-contained fuel cell
power plant with a continuous electrical rating of 200 kW. It is designed for automatic, unattended
operation, and can be remotely monitored. It can power electrical loads either in parallel with the
utility grid or isolated from the grid.
In summary, a landfill gas fueled power plant can be designed to provide 200 kW of electric output
without need for technology developments. The design would require selected components to increase
reactant flow rates with a minimum pressure drop. To implement the design would require non-recur-
ring expenses for system and component design, verification testing of the new components, and sys-
tem testing to verify the power plant performance and overall system integration. A thermodynamic
analysis of the fuel cell power plant optimized for operating on landfill gas was completed. The result-
ing performance of the landfill gas power plant is compared to a power plant operating on natural gas
in Table 22-3.
Table 23-3. Performance Comparison for Nominal 200 kW Output
Fuel
Electrical Efficiency (LHV) - %
Heat Rate (HHV) - Btu/kWhr
Available Heat - Btu/hr
Ambient Temperature for Fuel Water Recovery - °F
Startup Fuel
NATURAL GAS
POWER PLANT
Natural Gas
40
9,500
760,000
95
Natural Gas
LFG
POWER PLANT
Landfill Gas
36.4
10,410
825,000
95
Landfill Gas
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The estimated air emissions of the fuel ceil power plant is provided in Table 2.2-4. The fuel cell air
emissions are low because gas contaminants which could become emissions are removed by the gas
pretreater and fuel preprocessor. The air emissions are significantly lower than other landfill gas con-
version devices giving the fuel cell power plant the potential for being the best available control tech-
nology for landfill gas methane mitigation. Verification of these emission estimates will be a key ele-
ment of the demonstration program.
Table 2.2-4. Estimated Fuel Cell Air Emissions
Emissions - Lbs/106 Btu
NO,
so,
Particulates
Smoke
CO
Total Hydrocarbons
LFG FUEL CELL
0.02-0.04
0.00003
0.000003
None
0.04-0.08
0.02-0.03
Overall System Performance
The commercial application of the concept to the market described previously was assessed. For the
purpose of the evaluation, a site capable of supporting four fuel cell power modules was selected. The
site characteristics assumed are the typical values discussed earlier. The site would produce approxi-
mately 434,000 standard cubic feet of landfill gas per day. The gas contains approximately 50 percent
methane by volume with a heating value of 500 Btu per standard cubic foot. The system is capable of
supplying 784 kW of net electric power to the grid and has an available thermal energy of 3.36 million
Btu per hour. Overall system performance is outlined in Figure 2.2-5.
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FLARE GAS
EXHAUST
A
FUEL GAS
EXHAUST
LANDFILL
GAS
AIR
LFG
PRETREATMENT
SYSTEM
784 kW«
80.7 x 10«
BTU/DAY
LANDFILL GAS IN
217,300 SCFD CH4
217.300 SCFD CO,
188 SCFD NMOC
WASTE FILTER
MEDIA
GAS PRETREATMENT
SYSTEM EFFLUENT
AIR EMISSIONS
538,900 SCFD N2. O,, HjOyCO,, Ar
3.8 SCFD NMOC
1.05 LB/DAY NO,
1.6 LB/DAY SOj
5.8 LB/DAY HCL
SOUP WASTE
55 LB/YR FILTER MEDIA
V
ADSORBENTS
FUEL CELL OUTPUT
784 kW AC ELECTRICITY
80.7 X 10* BTU/DAY THERMAL ENERGY
AIR EMISSIONS
3,346,000 SCFD Nj, H,Cv. CO,, O,, Ar
4.0 LB/DAY NO,
SOLID WASTE
150 LB/YR SULFUR AND HAUDE
ABSORBENTS (30 LB/YR SULFUR AND MAUDES)
11tooA.
•10511
Figure 2,2-5. Overall System Schematic and Performance Estimate for Fuel Cell LFG-to-Energy
Conversion System
Impact of Heating Value on System Performance
Heating value of the landfill gas can vary from site to site or at a given site with time. The most signifi-
cant variation is a reduction in heating value from air intrusion into the landfill during energetic with-
drawal and collection of the gas. Although most of the oxygen in the air is consumed in the landfill,
nitrogen content of the gas increases thereby lowering the heating value of the gas.
Figure 2.2-6 shows the impact of changing the landfill gas heating value from 400 to 600 Btu/SCF on
fuel cell power plant heat rate and power output. In general, the lower the heating value of the gas the
lower the power plant thermal efficiency will be (or otherwise stated, the higher the power plant heat
rate will be).
The power output of a fuel cell power plant optimized to operating on landfill gas with 50 percent
methane is shown in Figure 2.2-6. A reduction in methane content or heating value below 500 Btu/SCF
result in a loss in energy input and power output. Above 500 Btu/SCF the power plant automatic flow
controls will self-adjust maintaining 200 kW output. In order to maintain 200 kW capability below 500
Btu/SCF some amount of natural gas blending may be required to maintain the gas heating value.
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FCR-11900A
200 p
-WITH NATURAL GAS BLENDING
11.500
9500
400
500 600
LANDFILL GAS HIGHER HEATING VALUE - Btu/SCF
11tOO-1«
M1220I
Figure 2.2-6. Impact of Landfill Gas Heating Value on Power Plant Power Output and Heat Rate
233 Environmental and Economic Assessment of the Fuel Cell Energy Conversion System
The commercial application of the energy recovery concept to the market described previously was
assessed. For the purpose of the evaluation, a site capable of supporting four fuel cell power plant
units is selected. The site characteristics, shown in Table 2.2-5, assumed are the typical values dis-
cussed earlier. The site would produce approximately 434,000 standard cubic feet of landfill gas per
day. The gas contains approximately 50 percent methane and has a gas heating value of 500 Btu per
standard cubic foot.
At a minimum the method for mitigating the methane and NMOC from landfill gas is installation of a
gas collection system and flaring of the gas. The fuel cell energy conversion system provides the oppor-
tunity for converting the methane in the landfill gas to useful energy. The baseline for the comparisons
in this system are the conventional option with flaring.
There are two significant differences between mitigation by flaring and mitigation with the fuel cell
energy conversion system. First, the fuel cell energy conversion system produces electric energy, ther-
mal energy and emissions offsets which can be used to generate revenues from the landfill gas mitiga-
tion system. Secondly, since the fuel cell converts methane to electricity more efficiently, it has lower
emissions at the site than competing options and provides significant emission offsets due to the re-
duction in emissions from the electric utility which would otherwise be providing the energy. These
differences are the basis for the assessment of the energy conversion system discussed in this section.
It should be noted that both the flare system and the fuel cell system essentially eliminate all methane
emissions from the landfill site and have a 98 percent destruction of the non-methane organic com-
pounds.
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Table 22-5. Site Characteristics for Landfill Gas Assessment
Landfill Gas Generation Rate
Bulk Constituents (vol %, dry)
• Methane
• CC>2 and Other Inerts
Contaminants (PPMV)
• Total Non-Methane Organic Hydrocarbons
• Total Sulfur
• Total Halides
• Methyl Chloride
• Vinyl Chloride
Gas Heating Value - Btu/SCF
434,000 SCFD
50
50
2700
21
132
14
7
500
Environmental Assessment
The analysis of the environmental impact shows that both the fuel cell and the flare system can be
designed to eliminate the methane and the non-organic methane compounds from the landfill gas sys-
tem. For the example site considered, the methane elimination is essentially complete for both systems
and 98 percent of the NMOC are destroyed. Trace amounts of SOX and NOX will be emitted in each
case. With the fuel cell system, however, significant reductions of NO* and SO* will be achieved due to
the fuel cell energy generation. This analysis assumes an 80 percent capacity factor for the fuel cell and
offsetting emissions from electric utility power generation using a coal-fired plant meeting New Source
Performance Standards. For the example site, the fuel cell energy conversion system provides 5.6 mil-
lion kWhr of electricity per year, with a net reduction of 352 tons* per year of NOX and 16.8 tons per
year of SO, from reduced coal use. These reductions can be used as environmental offsets, particular-
ly in critical areas such as California or other locations with severe environmental restrictions.
The environmental impact of application of the fuel cell concept to the potential market is shown in
Table 22-6. The data show that both the flare and the fuel cell mitigate methane and NMOC, under the
proposed standards and guidelines^. However, the flare merely converts these emissions to CO2.
acid rain, and other unhealthy pollutants. The fuel cell can provide a net reduction in global pollution
by offsetting energy production from coal.
Table 22-6 Emissions Impact of Fuel Cell Energy Recovery from Landfill Gas
Abatement
Technology
Venting
Only
Flare
Fuel Cell
Global Wanning
Methane
(Mg/Vr)
1.8 x 107
0
0
NMOC
(Mg/Yr)
510,000
10200
10,200
CO2
(Mg/Yr)
^—
4.94 x 107
-6.45 x 107
Acid Rain and Health
SO2
(Mg/Yr)
^—
Z972
-535,000
NO,
(Mg/Yr)
^—
29,720
-259,000
CO
(Mg/Yr)
^—
14,860
-8.620
(•)! ton - 907 kg
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International Fuel Cells FCR-11900A
Economically the fuel cell energy system has the potential for deriving revenues from electric sales,
thermal sales, and emission offsets credits. These revenues can be used to offset the investment cost
associated with gas collection, gas pretreatment, and fuel cell power units. The level of these revenues
depends upon the value of the electricity, the amount and value of the heat used, and the value of the
emissions offsets.
Economic Assessment Results
The fuel cell energy system has the potential for deriving revenues from electric sales, thermal sales and
emission offsets credits. These revenues can be used to offset the investment cost associated with the
gas collection, gas pretreatment and the fuel cell power units. The level of these revenues depends
upon the value of the electricity, the amount and value of the heat used and the value of the emissions
offsets.
Electric rates vary considerably with geographic location and the purchaser of the electric energy.
Commercial rates are applicable where the electricity can be used at the landfill or in nearby commer-
cial facilities. Commercial rates vary from a high of 13.68 cents per kWhr to a low 2.71 cents per kWhr.
The median rate in the United States is approximately 7 cents per kWhr. The rates charged to industry
are generally lower and are closer to the fully burdened avoided cost for the utility. These rates range
from 10.0 cents per kWhr to a low of 1.64 cents per kWhr with the mean value of approximately 5 cents
per kWhr. In general, both the commercial and industrial rates are higher in locations with high popu-
lation density and/or with air emissions problems. These locations are ideal for the use of the fuel cell
energy conversion system with its favorable environmental impact. Since the rates vary considerably.
the analysis in this section is done on a parametric basis for a wide range of electric rates.
The fuel cell energy conversion system was evaluated to establish the net revenues or costs for process-
ing landfill gas to mitigate methane emissions. For the purposes of the analysis it was assumed that the
fuel cell energy conversion system and the flare system would have an overall annual capacity factor of
80 percent. For this analysis, two levels of fuel cell installed cost were considered. The lower level,
$1500/kW represents a fully mature cost when the power plant has been accepted into the marketplace
and is routinely produced in large quantities. The upper level. $3000/kW installed, represents a price
level when the power plant is being introduced into the marketplace, and is produced on a moderate
and continuous basis.
The results of the analysis shown in Figure 22-1 describes the net revenues from the fuel cell energy
system as a function of the value received for the electricity produced in the fuel cell energy conversion
system. The case shown in Figure 2.2-7 assumes that 50 percent of the heat is recovered and that there
is an emissions offset credit The value of the heat recovered corresponds to the industrial value for
natural gas adjusted for the combustion efficiency to produce the thermal energy ($2.92 per million
Btu's). The value for the emission offset is $1000/ton for both NOx and SOx reductions. The net reve-
nue shown on the figure represents the income to the energy conversion system owner after all invest-
ment and operating costs have been recovered. When the value of the net revenue is less than zero, this
would represent a cost incurred for mitigating the methane from the landfill. For comparison pur-
poses the cost for mitigating with the flare option are also shown in Figure 2^-7. For the flare op-
tions.the costs include the cost of collecting and delivering the gas to the flare, the cost of the flare and
the operating cost for this system. For the electricity values where the fuel cell revenues are greater
than the flare option, the fuel cell would be the favored economic option. The cost for methane mitiga-
tion with a flare system is approximately $375 per million standard cubic fee of gas processed per year.
Based on the range of industrial and commercial electric rates in the United States, the fuel cell would
be the economic option in most locations at $1500/kW and would be the choice in those areas with
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FCR-11900A
average or higher electric rates at $3000/kW This indicates that there could be substantial opportunity
for efficient low emissions methane mitigation with the fuel cell power plant at product entry prices.
FUEL CELL INSTALLED COST
UJ 0
3 "
I »
s <
C o
O §
oc 5
u. 3
u.
Ill O
i o
Ulg
M
UJ
3000
2000
1000
-1000
•2000
MATURE
PRODUCT
COST
FUEL CELL
ECONOMIC OPTION
ENTRY LEVEL
COST
FUEL CELL REVENUES FROM
• ELECTRICITY
• EMISSION CREDITS
• THERMAL RECOVERY
FLARE ECONOMIC
OPTION
\
I
I
I
I
GAS COLLECTION
AND FLARE
I
2.0 4.0 6.0 8.0 10.0 12.0 14.0
VALUE RECEIVED FOR FUEL CELL ELECTRICITY ~ c/kWr
11800-18
R012108
Figure 2.2-7. Comparison of Fuel Cell to Flare for Methane Mitigation Assuming Electric Revenues
and Emission Credits
Figure 2.2-8 shows the fuel cell revenues for situations without heat recovery. Although the net reve-
nues are somewhat decreased, the results and areas of competitiveness are similar to those noted for
Figure 12-7.
Figure 22-9 shows the fuel cell revenues for the most stringent application situation. In this case, the
fuel cell receives revenues only from the sale of electricity. Although the emissions are lower from the
fuel cell, no specific credit or value is attached to them for this example. Under these conditions the
fuel cell is still the economic choice for most locations at $15007kW At $3000/kW it is still economical
in those areas where the value of electricity is nine cents per kWhr or higher. This would primarily be
areas such as California, New York, and parts of New England.
This analysis indicates that there is substantial market opportunity for the fuel cell energy conversion
system. At market introduction prices, the power plant would be applicable in locations with high
electric rates and situations where air emissions are quite severe. There are many areas of the country
which have these characteristics and they are increasing with time, thus indicating an ever increasing
market opportunity for the fuel cell power plants. These options were evaluated against the flare op-
tion which does not produce any useful energy. There are other energy conversion systems which could
produce electric and/or thermal energies. Comparisons to these options are discussed in the following
section.
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FCR-11900A
z
o
g s
E"
- »
3 O
Ul OC
Z a-
<
Figure 2,2-8. Comparison of Fuel Cell to Flare for Methane Mitigation Assuming Electric Revenues
and Emission Credits
o
O
C o
* d
2 g
o i
OC 3
u. 3
CA Ik
UJ O
3000
2000
1000
-1000
UJ
-2000
FUEL CELL INSTALLED COST
MATURE
PRODUCT,
COST
FUEL CELL
ECONOMIC OPTION
ENTRY LEVEL
COST
FUEL CELL REVENUES FROM
• ELECTRICITY
\
FLARE ECONOMIC
OPTION
I
I
GAS COLLECTION
AND FLARE
I
2.0 4.0 6.0 8.0 10.0 12.0 14.0
VALUE RECEIVED FOR FUEL CELL ELECTRICITY ~ c/kWhr
11900-21
911406
Figure 2.2-9. Comparison of Fuel Cell to Flare for Methane Mitigation Assuming Electnc Revenues
Only
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FCR-11900A
Comparison With Other Energy Conversion Options
The internal combustion engine and the gas turbine engine have been suggested as competing options
for methane mitigation at landfill sites. For the landfill size selected for this analysis, the internal com-
bustion engine is more effective than the gas turbine option for clean-up. This is used as the basis for
the comparisons in this section. The internal combustion engine can provide both heat and electric
energy while consuming the methane at the landfill gas site. With the present state-of-the-art technolo-
gy, however a lean-burn internal combustion engine has higher levels of NOx unless special precau-
tions are taken to clean-up the exhaust. For this analysis, two cases are considered. The first case
assumes there is no clean-up of the exhaust from the lean-bum internal combustion engine and the
second assumes that the exhaust is cleaned with selective catalytic reduction (SCR). Since the SCR
employs catalyst in the clean-up system, the landfill gas will have to be pretreated in a manner similar
to the fuel cell system. For those cases with the SCR clean-up system, a pretreatment system has also
been included as pan of the total system cost.
Figure 2J2-10 shows the results of the economic analysis for the fuel cell system and the internal com-
bustion engine system. Since both can provide electricity, the comparison between the systems are
based on the cost of electricity generated from the energy conversion system with appropriate credit
for thermal sales and/or emission offsets. For the case where the SCR is employed to clean-up the
engine exhaust, the fuel cell power plant is competitive with installed prices on the order of $3000/kW
If no exhaust clean-up is required for the internal combustion engines, then the fuel cell is competitive
at the fully mature price of $ 15007kW. In this latter case, however, the operation of the internal com-
bustion engine at the landfill site would be quite dirty and significant amounts of NOx would be added
to the ambient air. For many locations where the fuel cell would be considered, such as California or
other high emissions areas, the no exhaust clean-up option may not be available. Consequently, the
fuel cell option would be fully competitive with the internal combustion engine option for most cases
where on-site clean-up of the internal combustion engine is required.
1O.O
£ 8.0
*
1"
jg
s
2 «•<>
o
8 2-°
o
• ELECTRICITY SALES
• THERMAL RECOVERY
• EMISSIONS OFFSETS W|TH
-
15OOS/KW
'////
V/t'
w<
^wn
EXHAUST
CLEAN-UP
NO
EXHAUST
CLEAN-UP
FUEL CELL LEAN-BURN INTERNAL
ENERGY CONV COMBUSTION ENGINE
SYSTEM ENERGY CONV.
SYSTEM
11000-22
R9121M
Figure 2.2-10. Comparison of Fuel Cell to Internal Combustion Engine Energy Conversion System
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International Fuel Cells FCR-11900A
Based on the analysis of the flare and other energy conversion options, the fuel cell power plant is fully
competitive in all situations in the mature production situation. For initial power plant applications
with limited lot production, the fuel cell power plant is competitive in areas with high electric rates
and/or severe emissions restrictions at the local landfill site.
Conclusions
Based on the environmental and economic evaluation of the commercial fuel cell energy system, the
following conclusions can be made:
• The fuel cell landfill gas to energy conversion system provides net reduction in total emis-
sions while simultaneously mitigating the methane from the landfill gas.
• With the initial product prices, fuel cells will be competitive in landfill sites located in high
electric cost areas in sites with average commercial rates; where heat can be utilized or
where there is a credit for the environmental reductions from the fuel cell energy conver-
sion system.
• When the projected mature product price is achieved, fuel cells will be competitive for
most application scenarios. In many situations, fuel cells will provide net revenues to the
owners of the operating landfills. This could, in the long term, result in methane mitigation
without additional cost of any sort to the ultimate consumer.
2.2J Critical Issues
This section summarizes the key marketing and technical issues that must be resolved to verify the
commercial feasibility of the fuel cell landfill gas to energy conversion concept. Resolution of some of
these issues will come with the recognition of the long term economic value of the fuel cell in mitigating
landfill methane and NMOC emissions while significantly lowering secondary emissions and offset-
ting the air emissions from electric utility generators. Resolution of other issues will be achieved with
the design and successful demonstration of the pretreatment system and fuel cell on landfill gas. The
following marketing and technical issues need to be resolved:
Marketing Issues
• Market Entry at Initial Product Capital Cost - Market acceptance of the fuel cell energy
recovery concept must be achieved by entry into markets with the highest electric rates or
strictest emission controls. Federal incentives such as; low cost financing, emission cred-
its, etc. can hasten acceptance of the concept.
• Limited Electric Revenues - Electric utility avoided cost rates are impeding energy recov-
ery from sources such as landfill gas. Allowing revenues based upon the local commercial
or industrial rates, or fully burdened avoided costs would encourage energy recovery and
thus achieve the desired environmental impact.
• Available Uses of Thermal Energy - Fuel cell revenues increase with the sale of thermal
energy. Identification of thermal loads near landfills or arrangements to locate the fuel cell
at cogeneration sites near landfills (with gas pretreatment located at landfill) would im-
prove fuel cell market competitiveness.
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International Fuel Cells FCR-11900A
Technical Issues
• Verification of an Effective Pretreatment System - The pretreatment system design must
economically treat landfill gas to meet the long term sulfur and halide limits required by
the fuel cell. This demonstration program will verify the key process elements and steps of
the commercial system. The system and its elements must be optimized to produce a cost
effective commercial pretreatment system.
• Demonstration of Low Emissions - The demonstrator design and actual demonstration
will verify the low emission capability of the commercial fuel cell landfill-gas-to-energy
concept. This includes air emissions from both the fuel cell and pretreatment system as
well as solid and liquid effluents projected for the commercial system.
• Demonstrate Overall System Operabiliry. Durability and Reliability - A successful dem-
onstration will allow projection of a low operating cost component of the methane mitiga-
tion life cycle cost for the commercial system. This includes trouble-free unattended oper-
ation and minimal degradation (durability) of the regenerable beds.
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International Fuel Cells FCR-11900A
2.3 FUEL CELL LFG-TO-ENERGY SYSTEM DEMONSTRATION
This section describes the results of the Phase I program activity to define the fuel cell landfill-gas-to-
energy system demonstration. This activity includes the conceptual design of the fuel cell landfill gas
to energy system demonstrator which will be designed and tested in Phases n and HI, the selection of a
landfill site for the demonstration, determination of the site specific requirements affecting the dem-
onstrator design including codes, permitting requirements, site gas composition and clean up require-
ments, and establishment of the Phase n demonstration plan. This plan addresses the milestones and
timing of the site specific final design of the landfill gas pretreatment system, the natural gas power
plant modifications to accommodate landfill gas operation, and testing of the demonstrator to address
the key economic and emission issues. The overall objectives for this Phase I program are summarized
in Table 23-1.
Table 2.3-1. Overall Demonstration Phase I Objectives
• DEFINE AN OVERALL PRETREATMENT SYSTEM CONCEPTUAL DESIGN AND
PC25 FUEL CELL MODIFICATIONS WHICH WILL ADDRESS THE KEY MARKETING
AND TECHNICAL ISSUES AND LOW EMISSIONS OF A LANDFILL GAS TO ENERGY
FUEL CELL METHANE MITIGATION SYSTEM AT A TYPICAL LANDFILL GAS SITE.
• SELECT A LANDFILL SITE TO MEET DEMONSTRATOR OBJECTIVES.
• ESTABLISH A LANDFILL GAS PRETREATMENT SPECIFICATION AND SITE SPECIFIC
REQUIREMENTS FOR THE DEMONSTRATOR PRETREATMENT SYSTEM DESIGN.
• ESTABLISH THE PHASE II DEMONSTRATION PLAN.
2.3.1 Conceptual Design for Demonstrator
This section describes the demonstrator system and selected site, the fuel cell modifications to achieve
satisfactory power rating and efficient operation on landfill gas, the landfill gas pretreatment system
specification, site specific requirements, and the conceptual landfill gas pretreatment system design.
The conceptual design of the commercial system established key issues and system features requiring
demonstration. Table 2.3-2 outlines the objectives for the conceptual design of the landfill gas pretreat-
ment system and fuel cell modifications to allow operation on landfill gas. Introduction of these objec-
tives at this point provides an introduction to the scope of the activities covered in this section. These
objectives are discussed in detail in the sections describing the pretreatment and fuel cell systems.
Meeting these objectives will lead to a demonstration which verifies the feasibility of the commercial
product landfill gas methane and NMOC mitigation system. Therefore, the demonstrator will validate
the basic elements of EFC's commercial fuel cell landfill gas to energy product concept.
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imernauonal Fuel Cells FCR-11900A
Table 2.3-2. Conceptual Design Demonstrator Objectives
FUEL PRETREATMENT SYSTEM OBJECTIVES
PRODUCE A PRETREATMENT SYSTEM DESIGN WHICH BY DEMONSTRATION WILL:
• MEET LANDFILL GAS PRETREATMENT SYSTEM COMPONENT SPECIFICATIONS
AND SfTE SPECIFIC REQUIREMENTS
PERMITTING AND CODE REQUIREMENTS
CONTAMINANT LIMITS (FUEL CELL SUPPLY GAS)
OPERATING REQUIREMENTS (FLOWS, PRESSURES, STARTUP, SHUTDOWN, ETC.)
EMISSIONS (NOx, NMOC DESTRUCTION, LIQUID AND SOLID PRODUCTS)
LIFE (MATERIALS, COMPONENTS)
• DETERMINE TYPICAL PRETREATMENT SYSTEM EXIT TOTAL HALIDE LEVELS TO ENABLE
SIZING OF THE FUEL CELL HALIDE GUARD FOR THE COMMERCIAL PRODUCT.
FUEL CELL SYSTEM OBJECTIVES
DEFINE FUEL CELL MODIFICATIONS WHICH BY DEMONSTRATION WILL:
• VERIFY FUEL CELL DEMONSTRATOR PERFORMANCE ON CLEAN LANDFILL GAS.
• DEMONSTRATE OPERATION OF FUEL CELL HALIDE GUARD.
• DEMONSTRATE LOW AIR EMISSIONS ON LANDFILL GAS (NOX, CO, H/C).
2.3.1.1 Overall System and Site Description
Figure 2.3-1 provides a simplified description of the overall demonstrator fuel cell landfill-gas-to-ener-
gy system and site. The demonstrator consists of the landfill gas wells and collection system, a modular
gas pretreatment system and a PC25 natural gas fuel cell power plant modified for landfill gas opera-
tion. Landfill gas collected at the site is processed to remove contaminants in the pretreatment system.
This clean medium Btu landfill gas fuels the fuel cell power plant to produce ac power for sale to the
electric utility and cogeneration heat which, for the demonstration, will be rejected by an air cooling
module. A simplified process description of the landfill gas pretreatment and fuel cell systems is pro-
vided in Figure 23-2. All pretreatment and fuel cell process functions are described in this section.
The demonstration site has a landfill gas collection system in place. The Penrose site, whose selection
is described in Section 23.Z will provide compressed 85 psig gas to the gas pretreatment system, the
conceptual design of which is described in detail in Section 2.3.1.4. Since collection and compression
result in some condensed water, hydrocarbon and contaminants products, the existing site also has a
condensate collection and treatment system.
A slipstream of landfill gas from the site will be supplied to the demonstrator at a pressure of 85 psig,*
and will be regulated down to 10 psig. A first stage refrigeration condenser (~33°F) removes most of
the water contained in the saturated landfill gas and, based on Bio Gas Development experience, some
of the more easily removed heavier hydrocarbon and contaminant species in the gas. In the commer-
cial application, this condensate is vaporized and incinerated to avoid all site liquid effluents. Howev-
er, to avoid the extra cost and complexity for the demonstration we decided to return this condensate
to the existing site condensate treatment system.
(•) 1 psig - 6.89 kPa
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International Fuel Cells
FCR-11900A
Utility
power
lines
Gas wells and
and
collection system
Gas pre-
trcatment
system
PC25
fuel cell
power
plant
AC power
to grid
Landfill
Heat rejection
air cooling
module
FC3U27
Natural gas
MMO-07
•1010*
Figure 2.3-1. LFG Fuel Cell Demonstration Program
PC25 FUEL CELL
Figure 2.3-2. Demonstration Project Processes
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FCR-11900A
Landfill gas exiting the first stage refrigeration condenser is then sent to a molecular sieve dehydration
bed where the water content of the landfill gas is reduced to a -50°F dew point. This bed is periodically
regenerated with heated clean landfill gas (heated by a separate clean LFG fired heater) to restore its
dehydration function. During regeneration, a second fully regenerated bed takes over the function.
The same gas is also used to regenerate two other beds, activated carbon for NMOC removal, and an
H2S-specific molecular sieve. The gas is subsequently incinerated in a low NOX flare to destroy the
NMOC's and combust the H2S.
Following the molecular sieve dehydration step, the landfill gas proceeds to a second stage low temper-
ature refrigeration condenser (-25°F) where, based on Bio Gas Development experience, additional
high molecular weight NMOC species can be removed. The combination of first and second stage
refrigeration condensers act as a bulk remover of NMOC species. This increases the flexibility of the
pretreatment system to handle very high levels of landfill gas contaminants without need for modifica-
tion or increasing the size of the regenerable adsorption beds. This makes the system an all-purpose
LFG contaminant removal system. The effectiveness of the refrigeration condensate removal stages
will be monitored during the pretreatment system acceptance test. A challenge test exposing the sys-
tem to higher NMOC concentrations is being considered. The second stage refrigeration condenser
also greatly enhances the operation of the downstream activated carbon NMOC adsorption and mo-
lecular sieve H2S removal beds by reducing the gas temperature.
Next the landfill gas proceeds to the activated carbon bed which adsorbs the remaining NMOC's
including organic sulfur and halogen compounds. This is followed by a molecular sieve H2S removal
bed. The mol sieve for this bed will be selected and sized during the detail gas pretreatment system
design in phase n, based upon literature and vendor capacity and selectivity data for H2S versus CO2.
These beds are periodically regenerated as stated above with the regeneration gas being burned in a
low NO, flare. Second stage refrigeration condensate, which is easily vaporized, is incinerated along
with the regeneration gas in the flare. The flare (an enclosed type) achieves greater than 98 percent
destruction of all NMOC's by maintaining the combusted regeneration gas at a temperature of at least
1600°F for a residence time of at least one second.
In order to avoid the carryover of attrition products (dust) from the regenerable beds, the output gas is
filtered through a submicron filter.. It is estimated that less than 20 Ibs of attrited activated carbon and
molecular sieve bed material will be collected by this filter over the one year demonstration period.
A clean, dry, particulate-free medium Btu landfill gas exits the filter for consumption in the fuel cell. A
portion of this gas is extracted to provide regeneration gas. A backup natural gas supply is used to
initially qualify the fuel cell power plant before operation on landfill gas. Natural gas is also available
for blending with the landfill gas if needed to adjust the gas heating value for the demonstration test. It
is estimated that approximately six percent natural gas blending will provide a heating value of 500
Btu/SCF (based on an average landfill gas heating value of 470 Btu/SCF on a dry basis).
Clean landfill gas is convened in the fuel cell power plant to ac power and heat. Details of the fuel cell
preliminary design are described in Section 2.3.12. The general fuel cell system consists of three major
subsystems - fuel processing, dc power generation in the fuel cell stack and dc to ac power condition-
ing by the inverter.
A halide guard will be added to the existing fuel processing system in the fuel cell power plant to scrub
residual halides slipping by the pretreatment system. The addition of the halide guard to the fuel cell is
an addition to the present capability of removing residual sulfur and any oxygen in the gas, and is
significant because it simplifies the design of the pretreatment system. The added halide guard also
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FCR-11900A
provides protection in the event of a system or site upset. The resulting fuel is steam reformed to
produce hydrogen for the fuel cell stack.
The fuel cell converts hydrogen and the oxygen in air electrochemically to produce ac power and heat.
The waste heat will be rejected by an air cooling module. The ac power will be transformed and deliv-
ered to the utility grid.
2J.I.2 Fuel Cell System Preliminary Design
This section covers the modifications to the basic PC25 natural gas power plant to allow operation on
clean medium Btu landfill gas. A photograph of the PC25 prototype power plant is shown in Figure
2.3-3. A functional schematic and listing of modification and improvement options to improve halide
tolerance and increase rated power capability on landfill gas are provided in Table 2.3-3. These options
will be reviewed in this section.
Table 2.3-3 identifies the changes to the 200 kW PC25 fuel cell power plant to allow operation and to
increase rated power capability on landfill gas. Most of these changes are needed as a result of the
lower heating value, higher gas density, and higher volumetric throughput and pressure drops asso-
ciated with landfill compared to natural gas. The first three changes would only provide a capability of
80 kW on 500 Btu/SCF landfill gas compared to 200 kW on nominal Btu/SCF natural gas. An addi-
tional change of increasing the capacity of the inlet fuel controls increases the demonstrator power
plant capability to 140 kW. These modifications can be made in the field, with minimum risk and cost
following checkout and qualification of the fuel cell on natural gas. Changes 5 and 6 are required for
175 kW capability and require redesign of the fuel ejector and redesign of the burner fuel plumbing to
reduce pressure drop. Changes 7 through 9 are more extensive and are required to achieve 200 kW
capability. The changes to achieve 140 kW will be considered as the baseline, and the changes to
achieve 175 kW will be carried as an option to be considered in Phase II of the program. If higher
power levels above 175 kW are desired this could be accommodated in Phase III of the program by
subsequent changes in additional fuel cell equipment
At a rating of 140 kW the heat rate of the PC25 fuel cell power plant operating on 500 Btu/SCF landfill
gas is projected to be 10,200 Btu/kWh. Recoverable heat down to 160°F is estimated at 510,000 Btu/hr.
Pubs 8539
Figure 2.3-3. Photograph of the PC25 Prototype Power Plant
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Table 2.3-3. Improvements to PC25 Landfill Gas Power Plant
140 kW
ACHIEVEMENT OF INCREASED RATED POWER CAPABILITY
. MODIFY CONTROL SOFTWARE (SWITCH FROM NATURAL GAS TO
HIGHER DENSITY, LOWER HEATING VALUE LFG)
!. CHANGE CATHODE EXIT ORIFICE (REDUCE PRESSURE DROP)
3. CHANGE FUEL PROCESSING SYSTEM RECYCLE ORIFICE (REDUCE
PRESSURE DROP)
4. LARGER CAPACITY INLET FUEL CONTROLS (REDUCE PRESSURE DROP)
5. HIGHER HEAD RISE EJECTOR (PUMP HIGHER DENSITY, LOWER HEATING
175 kW «£ VALUE LFG AND OVERCOME HIGHER PRESSURE DROP)
6. LOW PRESSURE DROP REFORMER BURNER FUEL INLET NOZZLE
(REDUCE PRESSURE DROP)
7. HIGHER HEAD RISE AIR BLOWER (OVERCOME INCREASED PRESSURE
DROP)
9OO kU/ -J
** 8. LARGER ANODE EXIT NOZZLE AND PIPE (REDUCE PRESSURE DROP)
9. LARGER ANCILLARY COOLANT PUMP (INCREASING COOUNG TO
MAINTAIN 05*F DAY WATER RECOVERY CAPABILITY)
IMPROVED HALIDE TOLERANCE
10. ADD HAUDE GUARD TO LOW TEMPERATURE FUEL PREPROCESSOR
(ALLOW HIGHER PRETREATMENT SYSTEM EXIT HAUDE SUP TO
REDUCE DEMANDS ON PRETREATMENT SYSTEM)
START UP ON LANDFILL GAS
11. MODIFY START BURNER (ALLOWS HEAT UP ON LOWER HEATING
VALUE LFG - NOT REQUIRED FOR DEMONSTRATOR WHICH WILL
USE NATURAL GAS FOR START BURNERS
Figure 23-4 demonstrates the impact of landfill gas halide level on PC25 fuel processor life. A pre-
treatment system would have to be designed to achieve total halide removal down to 0.15 ppmv to
ensure a one year fuel processor life. This does not include contingency for the possibility of upsets of
the site, the collection system or pretreatment system. To mandate this halide level or lower would
impose a severe complexity and cost burden on the pretreatment system. The addition of a conven-
tional commercial halide guard bed to the existing fuel preprocessor will provide increased fuel pro-
cessor protection. A commercial halide guard is typically a promoted activated alumina material
which has a high affinity for hydrogen and halogens. Trace light halogen compounds such as vinyl
chloride or freons, exiting the pretreatment system are readily hydrogenated to HCL and HF in the
fuel preprocessor and absorbed on the commercial guard material down to low parts per billion levels
in the gas. This same process has been validated in naphtha-fueled fuel cell power plants where organ-
ic chloride contamination of the fuel is a concern.
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FCR-11900A
1.51—
UJ
uQ 1'°
Q CC
d 0.5
PC25 LOAD FACTOR = 0.8
1300 HOURS UFE
AT 1.0 PPMv
I
I
I
I
I
I
8000 HOURS UFE
AT 0.15 PPMv
I
1I80O-14
800208
0 2000 4000 6000 8000 10,000
FUEL PROCESSOR LIFE (HOURS)
Figure 2.3-4. Fuel Processor Life vs. Landfill Halide Level
Halide protection can be accomplished by removing approximately 1/3 of the present sulfur absorp-
tion guard material (which is currently designed for 3 ppmv average sulfur for 5 year life) and replacing
it with sufficient halide guard material to remove 3 ppmv halide from LEG for one year. This can be
accomplished while leaving sufficient sulfur absorption capacity for the one year demonstration in
Part m. Another option is to place a separate bed of halide guard material after the fuel preprocessor.
Final selection of the best halide guard placement option will be decided in the Phase n Site Specific
Design. If the pretreatment system is capable of achieving total halide levels below 0.5 ppmv this same
halide guard volume would protect the fuel processor for up to five years; this equals the fuel processor
catalyst life for the commercial power plant. Conversely, at higher pretreatment halide exit levels a
larger halide guard can be designed to provide longer life.
2.3.1.3 Landfill Gas Pretreatment System Specification and Site Specific Requirements
The landfill gas pretreatment system specification establishes the technical requirements for guiding
the Bio-Gas Development Inc. pretreatment demonstrator design. The complete gas pretreatment
system component specification (FCCS 5736) can be found in Appendix A. This specification in-
cludes applicable standards, state and local codes, all technical requirements, and quality assurance
requirements. The technical requirements include output gas quality to the fuel cell, operating condi-
tions including start-up/shutdown/normal operation, pressure regulation, contaminant disposal, life.
permitting, design and construction, and documentation requirements.
The output gas requirements are summarized in Table 2J-4. These requirements include allowable
sulfur and halide limits, paniculate levels, dew point and operating flows, and the pressure and tem-
perature of the landfill gas supplied to the fuel cell. The allowable limits on total sulfur and halides
provide a readily achievable requirement which should result in a lower cost commercial pretreatment
system.
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FCR-11900A
Table 2.3-4. Output Gas Requirements to Fuel Cell Power Plant
Flow
Pressure
Temperature
Dew Point
Total Sulfur
Total Halides
Particulates
Minimum
0
4
30
—
—
—
^^
Maximum
5000
14
130
20
3
3
Units
SCFH
Inches of Water
Column
-F
•F
PPMV
PPMV
Particulates removal of 100% at 1 micron or larger and
98% removal at 0.4 microns or larger
Two final elements have been added. These include a summary of the local permitting requirements so
that the pretreatment system can be permitted at the Penrose site with minimum difficulty and an
expanded analysis of trace contaminants in the gas at Penrose for fine tuning the demonstrator pre-
treatment system preliminary design.
Table 23-5 lists the local permits presently required at the Penrose site. This list shows 30 permits
which have been obtained from the South Coast Air Quality Management District, the City of Los
Angeles, Los Angeles County, the State of California, and the U.S. EPA. In addition, a list of prelimi-
nary permit requirements is being developed based on the Bio-Gas pretreatment system preliminary
design (See Section 2.3.1.4) including equipment, size and weight, interface requirements, utilities, and
the expected gaseous, liquid and solid wastes anticipated to result from the demonstration. This list
will be utilized to make contacts with various permitting agencies to define the final permitting re-
quirements for this demonstration in Phase U.
Table 23-6 lists the range of landfill gas constituents at the Penrose site which can provide a number of
optional gas mixtures from both Penrose and adjacent sites. Sulfur compounds, volatile priority pol-
lutants including halogenated species, and major hydrocarbon species are listed. This tabulation is
based on data taken recently at Penrose and adjacent sites (see Appendix B). A complete character-
ization of the landfill gas will be repeated for the pretreatment system acceptance test during Phase II
using EPA and SCAQMD approved methods.
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FCR-11900A
Table 2.3-5. List of Permits for Penrose Site
Agency
SCAQMD
(043535)
SCAQMD
SCAQMD
SCAQMD
SCAQMD
SCAQMD
SCAQMD
SCAQMD
SCAQMD
SCAQMD
SCAQMD
SCAQMD
SCAQMD
SCAQMD
SCAQMD
LA City
LA City
LA City
LA City
LA City
LA City
LA City
LA County
LA City
LA City
LA City
LA City
State of Calif.
EPA
Type of Permit
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Air Pollution
Ind. Safety
Ind. Safety
Ind. Safety
Industrial Waste
Occ. Cart
Fire Dept.
Fire Dept.
Fire Dept.
Public Health
Lie.
Fire Dept.
Fire Dept
Fire Dept
Bd. Equalization
Haz Waste Gen.
ID#
Permit Number
155945
156443
158444
158445
156446
156447
156448
155951
155950
155849
155948
155947
161452
152625
155946
A-76778
A-77143
A-77144
W-441246
LA08723/85
66024
66025
509222
558299-25
66024
66025
HYHQ36-0202150005
CAD 981 460 892
Object Permitted
Cond. Accum.
*\ Eng.
#2 Eng.
«Eng.
#4 Eng.
#5 Eng.
#6 Eng.
#1 Flare
ft. Flare
#3 Flare
#4 Flare
#5 Flare
Cool. Ywr.
Gas Chill.
Used Oil Tnk.
Air lank
Air Tank
Air Tank
Ind. Waste
Facility
Vapor Rec. Sys.
Vapor Rec. Sys.
Haz. Materials
Haz. Waste
Haz. Material
Industrial Processing
System
Industrial Processing
System
Date Issued
7-18-88
10-13-88
10-13-88
10-13-88
10-13-88
10-13-88
10-13-88
8-1-86
7-10-86
7-10-85
1-1-85
6-30-86
5-8-90
5-8-90
11-1-89
2-2-89
8-24-87
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Table 2-3-6. Range of LFG Constituents at Penrose
Sulfur (ppmv)
H2S
Methyl Mercaptan
Ethyl Mercaptan
Dimethyl Sulfide
Dimethyl DisulGde
Cartonyl Sulfide
Carbon Disulfide
Tbtal Sulfur, as H2S (ppmv)
Volatile Priority Pollutants (ppmv)
Dichloroethene
Dichloroe thane
Benzene
Chlorobenzene
Ethylbenzene
Methylene Chloride
Styrene
IrichJoroethene
Thchlorofluoromethane
Toluene
Tetrachloroethene
Vinyl Chloride
Xylene Isomers
CIS-L 2-Dichloroethane
Major Hydrocarbon Species (vol %, dry)
Methane
Ethane
Propane
Isobutane
N-Butane
Isopentane
N-Pentane
Hexanes
103.0
3.0
0.5
8.0
0.02
<0.5
<0.5
114.5
0-33
0-0.25
0.4-2.0
0.1-1.0
3.5-B.O
0-12.0
0-0.5
0.6-2.8
0-0.6
4.7-35.0
1.0-6.3
0.4-1.4
6.9-22.0
4.1-5.1
41-48
0
0
0-0.01 (100 ppmv)
0
0-0.097 (970 ppmv)
0-0.018 (180 ppmv)
0.0040-0.039 (390 ppmv)
Total Chloride as CL (ppmv) 14.5-67.1
Total Volatile Priority Pollutants (ppmv) 21.7-1053
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2J.I.4 Gas Pretreatment Conceptual Design
This section covers the specific details of Bio Gas Development Inc. conceptual design of the landfill
gas pretreater for the demonstrator. The conceptual design is based on the requirements set forth in
the landfill gas pretreatment system specification and on the experience gained with the commercial
landfill gas cleanup system designed for the 12 MW Johnston, R.I. landfill site. The demonstrator
design (and future commercial designs) incorporate improvements which will minimize liquid and
solid wastes and provide enhanced capability for handling a wide range of varying contaminant con-
centrations at different landfills.
Figure 2.3-5 shows the features of the Johnston, R.I. landfill gas cleanup system. Table 2.3-7 lists the
full range of improvements that would be incorporated in going from the R.I. cleanup system to a
commercial concept pretreatment system to the pretreatment system for the demonstrator. Changes
from the R.I. system will include reducing the scale of process flow from 12 MW to a nominal 200 k W,
and reducing operating pressure from 60 psig to 7 psig to minimize landfill gas pumping parasite pow-
er.
The sources of solid waste products in the R.I. system will be eliminated. The non-regenerable zinc
oxide and permanganate beds are being replaced with regenerate molecular sieve beds.
A very significant change is the addition of two landfill gas refrigeration and condensing stages to
significantly reduce water and heavy NMOC loading on the regenerable desiccant and activated car-
bon beds. The second colder condensing stage is a proprietary process which not only allows the acti-
vated carbon and H2$ removal regenerable beds to be operated at a low temperature to optimize their
performance but also provides a means to reduce the concentration of high molecular weight com-
pounds such as siloxanes which are not removed in the first condensing unit. Total parasite power of
the commercial pretreatment system including the landfill gas blower and the two refrigeration stages
is estimated to be about two percent of the fuel cell net power.
AN
FCM7I2
DEVELOPMENT INC
6A.
GAS GUARD BkTQtT PCNQBC
•HONE
Figure 2,3-5. Commercial Landfill Gas Cleanup in Rhode Island
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International Fuel Cells FCR-11900A
TABLE 2.3-7. PRETREATMENT SYSTEM MODIFICATIONS
COMMERCIAL CONCEPT
• SCALE FROM 12 MW TO 800 KW.
• REDUCE DESIGN PRESSURE FROM 60 PSIG TO 7 PSIG NOMINAL.
• ELIMINATE CONDENSING AND STORAGE OF ALL DESORBED CONTAMINANTS.
ADD LOW NO* INCINERATION OF ALL DESORBED CONTAMINANTS, AND
VAPORIZE AND INCINERATE ALL LIQUID PRODUCTS.
• ELIMINATE NON REGENERABLE (SOLID WASTE) ABSORBENT ZINC OXIDE AND
PERMANGANATE BEDS AND ADD REGENERABLE MOLECULAR SIEVE H2S
REMOVAL BEDS.
• ADD TWO LFG REFRIGERATION AND CONDENSING STAGES TO ENHANCE
WATER, VOC, HALIDE AND SILICON COMPOUND REMOVAL.
• INTEGRATE INCINERATOR AND REGENERATION GAS HEATER FUNCTIONS.
RECOVER HEAT FROM INCINERATOR.
DEMONSTRATOR
• RETURN WATER AND HYDROCARBON CONDENSATE (99.5%/H2O) FROM FIRST
STAGE REFRIGERATION CONDENSER TO EXISTING SITE LANDFILL GAS
COMPRESSOR AND COOLING CONDENSATE TREATMENT SYSTEM TO
ELIMINATE NEED FOR REVAPORIZATION HEAT RECOVERY UNIT.
• UTILIZE SEPARATE LOW NOx FLARE AND CLEAN LANDFILL GAS FIRED
REGENERATION GAS HEATER.
Overall thermal efficiency of the commercial pretreatment system will be enhanced by using a heat
recovery unit to extract heat from the incineration exhaust and provide energy for preheating of regen-
eration gas and vaporizing liquid refrigeration condenser products. It is estimated that the thermal
efficiency of the commercial version of the pretreatment system (heating value of gas delivered to the
fuel cell vs. heating value of raw landfill gas supplied to the pretreater will be approximately 92%).
About 8 to 16 percent of the clean landfill gas processed by the pretreater will be used for regeneration
and will provide by incineration the energy for regeneration gas preheating and condensate vaporiza-
tion.
The smaller nominal 200 kW demonstrator pretreatment system incorporates all of the major features
of a commercial system except in those areas where it is expedient to simplify the design to reduce the
cost of the demonstrator without sacrificing verification of critical features of the commercial system.
Table Z3-7 lists these simplifications which eliminate the need to incorporate an integrated incinerator
and heat recovery unit, allowing the use of a smaller enclosed low NOx ground flare. Figure 2.3-6 shows
a process flow diagram of the demonstrator landfill gas pretreatment system. Since the Penrose site
has an existing and permitted condensate collection and pretreatment system, this will be used to treat
the condensate from the first refrigeration condenser only (the smaller condensate from the second
condenser is easily vaporized and will be incinerated in the flare). The use of a separate landfill gas
fired heater to heat regeneration gas rather than energy recovery will result in a lower pretreatment
thermal efficiency than in the commercial system. Specific design details and performance of the dem-
onstrator pretreatment system design are discussed later in this section. The resultant system is de-
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International Fuel Cells
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signed to meet the requirements of the pretreatment specification and should allow through its actual
demonstration, verification of the design and meeting of the key objectives of this program.
The pretreatment system is a demand system providing a regulated supply of clean landfill gas of up to
5000 SCFH (120,000 SCFD) at 4 to 14 in. H2O to the fuel cell. A continuous and uninterrupted gas
supply is guaranteed by completing the required regeneration of the beds in a shorter time (approxi-
mately 7 hours) than the adsorption cycle (approximately 8 hours). This allows the adsorbing bed and
the freshly regenerated bed to be put on line in parallel flow (adsorption mode) prior to switch over and
beginning the regeneration of the depleted adsorbing bed. Pretreatment system operating supply
pressure is sufficient to overcome all system pressure drops in the pretreatment system ensuring an
adequate gas supply to the fuel cell. The pretreatment system supply pressure is approximately 10
psig. This would be reduced by further optimization to seven psig in the commercial version.
RMCNOAS
HEATER
COMDDttATE
PEN ROSE
COMPRCSBOR
ANOCONOENSATE
SSSKft^0 CONOENSATE
J"J*J«JO*T TREATMENT
SYSTEM Avarni
(WPSM) VnJWM
FLAME
TO FUEL CELL
OH PEN ROSE
LOW PRESSURE
LFO COLLECTION
SYSTEM
4-14 IN. H,O
SUPPLY PRESSURE
TO FUEL CELL
•10(11
Figure 2.3-6. Demonstrator LFG Pretreatment System
A dew point of approximately -50°F is achieved in the gas by means of the first refrigeration condenser
and regenerable molecular sieve dehydration bed. The condenser also reduces the water loading in the
dehydration bed increasing overall effectiveness and minimizing dehydration bed size. The combined
action of the two condensing stages in removing the bulk of the NMOC's and the substantial reduction
in temperature makes the activated carbon bed an effective polishing bed for minimizing halides and
organic sulfur compounds. Effectiveness of the molecular sieve H2S removal bed is also enhanced
greatly by its low operating temperature to ensure that the specification allowable contaminant levels
for sulfur will not be exceeded. A final paniculate filter ensures the meeting of specification panicu-
late limits. Lastly, heating by ambient air will increase the temperature of the clean landfill gas
supplied to the fuel cell to within specification limits.
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International Fuel Cells FCR-11900A
Although incineration of pretreatment by-products will be combined with heat recovery in a commer-
cial system, a separate enclosed flare and regeneration gas heater will be used in the demonstrator.
The flare will be designed for low NOx meeting South Coast design specifications. It will also be de-
signed to preclude dioxin formation and have a destruction efficiency consistent with South Coast
design specifications.
Bio-Gas Development Inc. has completed a conceptual design of the demonstrator landfill gas pre-
treatment system. They provided: a P&ED drawing showing all process, vaJving instrumentation and
safety equipment; a system mass balance describing process temperatures, pressures, major and con-
taminant species; heat balances at major process steps; process calculations; and an equipment list
including all major process components, valves, and instrumentation including qualified manufactur-
ers, materials of construction and size where applicable.
The overall pretreatment package would consist of a skid-mounted modular assembly approximately
ten feet* in length by eight feet in width by nine feet in height weighing approximately 10,000 Ibs. ** An
enclosed flare, approximately two feet in diameter by 18 feet in height above ground, would be shipped
horizontally and erected as part of the pretreatment package at the site. All equipment is self con-
tained and is readily accessible for inspection and maintenance as required.
The pretreatment system will be installed at the site and receive raw landfill gas from the existing Pen-
rose supply. This gas has been filtered and undergone compression and cooling to 80-100°F (and the
removal of condensate). The supply feeds both the existing internal combustion engines at Penrose
and the fuel cell demonstrator at the site. This compares with a commercial version of this system
where landfill gas would be collected, undergo some condensate removal, be filtered and compressed
to about seven psig by a blower, and supplied to the pretreatment fuel cell system. The landfill gas is
regulated to the pretreatment system inlet pressure of 10 PSIG (13 psig maximum working pressure).
Pressure losses in the pretreater lower the pressure to about three psig where it is then regulated to the
fuel cell supply pressure of 4-14 inches H2O gage.
The system consists of seven major subsystems:
1. First stage refrigeration condenser and condensate removal.
2. Molecular sieve dehydration regenerable beds.
3. Second stage refrigeration condenser.
4. Activated carbon hydrocarbon and NMOC polisher regenerable beds. H2S removal molecular
sieve regenerable beds, and paniculate filter.
5. Regeneration gas heater and regeneration varying subsystem.
6. Enclosed flare.
7. Refrigeration system to provide coolant to condensers.
The first refrigeration condenser consists principally of a liquid coalescing separator for removing
condensate which may be formed during expansion of the inlet raw landfill gas from 85 psig to 10 psig,
the first stage refrigeration condenser and another coalescing separator for removing condensate en-
trained in the gas leaving the condenser. Water and hydrocarbon removed from these devices is col-
lected in a condensate blowdown tank for transfer to the existing Penrose condensate collection and
treatment system. Also included in the subsystem is a cold brine circulation loop which rejects heat
from the condenser to the refrigeration subsystem.
(•) 1 ft - 03 m
(••) I Ib - 0.45 kg
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International Fuel Cells FCR-11900A
The molecular sieve dehydration beds remove the remaining water in the gas to less than -50°F dew
point and protect downstream equipment from freezing. Removal of water by condensation in the first
stage condenser reduces the water loading on this molecular sieve allowing the design of a smaller bed.
The second stage refrigeration condenser subsystem together with the first stage condenser, removes
many of the heavy NMOC's from the landfill gas and enhances the capability of the overall system to
remove difficult light halogenated species and silicon compounds. Also included in this subsystem is a
cold brine loop which rejects heat from the condenser to the refrigeration subsystem.
The remaining low temperature dry process units, the regenerable activated carbon beds, the regener-
able molecular sieve beds and the paniculate filter complete the gas cleanup process by respectively
polishing the remaining NMOC's including organic sulfur and halogen compounds, removing H2S,
and preventing fine and attritted material from these beds from reaching the fuel cell. Total sulfur as
HiS exiting the pretreatment system is estimated to be less than 3 ppmv. Total halide, as chloride, is
estimated to be negligible exiting the activated carbon bed (approximately 5 ppmv entering the bed).
These values are all subject to verification in Phase n of this demonstration program.
Final sizing and selection of specific adsorbent bed materials will be made in the Phase II demonstra-
tor pretreatment final design process. Final bed sizing, bed material selection, adsorption and regen-
eration cycle length will be based on vendor calculations (plus a factor of safety) for the specific adsor-
bent material heat capacity and properties and the specific environmental working conditions during
the adsorption and regeneration cycles. One specific issue that has been raised is the interference of
CO2 in the H2S removal molecular sieve. Vendor experience will be used in the selection and sizing of
the molecular sieve to minimize potential interference and to calculate the required molecular sieve
bed volume to compensate for any interference. The allowable fuel cell sulfur specification of 3 ppm V
also allows for a significant sulfur slip from the pretreatment system to ease the requirements placed
on the molecular sieve bed. Verification of adsorbent bed effectiveness will be done by gas analysis
during the Phase n pretreatment system acceptance testing. A challenge test exposing the beds to
higher than usual contaminant levels and an extended cycle test to determine potential breakthrough
(or lack thereof) of specific contaminants is being considered.
Regeneration of the molecular sieve dehydration beds, activated carbon beds and H2S removal molec-
ular sieve beds is achieved by diverting approximate 16 percent of the clean landfill gas counterflow
and in series through these respective beds. A preliminary staged regeneration sequence was de-
scribed earlier in Section 22.1, Figure 2-2-3. Sample calculations of bed regeneration thermal require-
ments and heat balances are provided in Appendix C. In the larger commercial fuel cell version only
about eight percent of the clean landfill gas will be required for regeneration. During the first half of
the regeneration period (approximately four hours), this regeneration gas is heated by the regeneration
gas heater to approximately 550 °F to heat up and regenerate the beds. The regeneration gas heater is
fired with one percent of the clean landfill gas during this period. As the beds successively reach their
desired regeneration temperature, the regeneration gas flow can be bypassed around that bed so as not
to overheat the bed. For the next four hours, the regeneration gas heater is bypassed (heater also
turned off) to cool the adsorbent beds. Following cooldown, the freshly regenerated beds are slowly
brought back to operating pressure (equalized) by opening small bleed valves between each bed and its
twin adsorbing bed. Both beds are operated in parallel flow for a few minutes before beginning the
regeneration cycle on the depleted adsorbent bed which will have been in the adsorbing mode for
about eight hours. The timing and sequencing of all pneumatically activated valves is controlled by a
programmable computer which provides high flexibility in fine tuning and adjusting the system.
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international Fuel Cells FCR-11900A
Regeneration gas and vaporized condensate from the second stage refrigeration system is burned in an
enclosed flare. The flare is rated at greater than 99 percent NMOC destruction efficiency.
Cooling of the first and second stage refrigeration condensers is provided by a single refrigeration
system which removes heat from the cold brine loops in the first and second stage condenser subsys-
tems. Total power requirement of the pretreatment system including the refrigeration compressor is
estimated at about 6 kW or about three percent of a nominal 200-kW fuel cell. This compares with
about a two percent parasite load projected for an optimized 800 kW commercial landfill gas to energy
fuel cell system.
The remainder of the Bio-Gas landfill pretreatment system details provide for manual startup of the
unit, automatic monitoring of unattended operation, both manual and automatic shutdown in re-
sponse to out of limits pressure and temperature conditions and safety systems including pressure
reliefs to protect the system from over pressure (13 psig maximum working pressure).
Early in Phase 0 of the program, a specific pretreatment system checkout, commissioning and verifi-
cation test program will be developed to document pretreatment system performance later in Phase II
including contaminant removal and air emissions. A challenge test will be devised to verify pretreat-
ment system performance at higher raw landfill gas contaminant levels. It is envisioned, at this time,
that this challenge test will consist of subjecting the pretreatment unit to increased levels of a known
light easily handled, but difficult to remove, halogenated freon compound.
U.I.5 Overall Demonstrator Performance
This section presents a preliminary prediction of the overall performance of the demonstrator landfill-
gas-to-energy fuel cell conversion system. The case selected is for a net fuel cell output of 140 kW The
raw landfill gas flows have been scaled to be consistent with the lower fuel cell demand of 69,000 SCFD
of clean gas. Regeneration gas flows are based on 16 percent of the landfill gas flow for regeneration
gas and one percent for regeneration gas heating.
Figure 23-7 summarizes the estimated overall performance of the demonstrator including raw landfill
gas input flows based on a 500 Btu/SCF methane, CC>2 mixture and 1745 ppm NMOC's which is the
maximum possible contaminant level at the Penrose site, net electrical output, available thermal ener-
gy, pretreatment and fuel cell exhaust flows and air, liquid and solid effluents. Overall performance is
similar to a scaled down version of the commercial system presented in Section 2.2. Very low air emis-
sions and solid products are generated as in the commercial system. No sulfur or halide solid products
are handled on site since all bed refurbishment is done at the factory as discussed earlier in this sec-
tion. The only exception to the commercial system is the return of the pretreatment first stage refriger-
ation condenser liquid products (mostly water) to the existing Penrose condensate treatment system.
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International Fuel Cells
FCR-11900A
REGENERATION EXHAUST
FROM FLARE. REGEN. GAS HEATER
-200,000 SCFD OF N2, O,
HjOv.COj.A,,
-1 SCFD NMOC-t (>99% DESTRUCTION)
- 0.4 IBS/DAY NOX (O.06 LBS/MMBTU)
LANDFILL GAS
41,500 SCFD CH2
41,500 SCFD COj
145 SCFD NMOC's
PRETREATMENT
PARASITE POWER
FROM SITE
~«kW
= >
A
LFG
PRETREATMENT
SYSTEM
FUEL CELL
69,000 SCFD
SCF CLEAN
LFG
FUEL CELL EXHAUST
- 530,000 SCFD OF N,. H20, CO*
OJ.A,,
- 0.7 IBS/DAY NO* (0.02 LBS/MMBTU)
NET ELECTRICAL
POWER
140 kW
AVAILABLE THERMAL
ENERGY
12-2X10* BTU/DAY
V
LIQUIDS
.-40LM/DAY
OONOemATE
WATtMAND
HYMOCANBON
TOPCNROW
CONDENSATE
TREATMENT
tVSTEU.
(VAPORIZED*
INONEHATED
IN COMMERCIAL
SVSTEM)
V
SOLIDS
•MAXIMUM ID
= =>
ACT. CARBON
AMOMOL
•IEVE DU1T
ON FILTER.
•NO SULFUR
Oft HALJDC.
SOLIDS
• APmOXlMATELV
• LM/VR TOTAL
•ULFURANO
HAUOC
ABSORBED ON
tORBENTBOW
1HOOAA-I
•11211
Figure 2.3-7. Overall Performance Estimate for Demonstrator Fuel Cell Landfill Cos To Energy
Conversion System (1 Year Demonstration)
SELECT LANDFILL SITE TO MEET DEMO OBJECTIVES
The objective of the site selection effort was to select the best available site for demonstrating the re-
covery of energy from landfills using fuel cells. The approach was to establish site selection criteria
from the conceptual design of the commercial product; apply these criteria to potential landfill sites
identified by Pacific Energy, and then downselect and rank these sites according to the criteria. Based
on this evaluation. Pacific Energy's Penrose Power Station in Sun Valley, California, was selected as the
site for the demonstration.
2J.2.1 Site Selection Criteria
Two major site selection criteria were established for selecting the demonstration site. These criteria
are:
(1) That the site be representative of U.S. landfills, so that the demonstration will be relevant to a
large portion of the U.S. market; and
(2) That the site be suitable, with existing and reliable gas supplies and facilities available.
The first selection criterion, that the site be representative, requires that the landfill gas available at
this site be typical of the majority of sites across the United States in major gas composition, heating
value and contaminants. Equally important, is that the local codes and regulations be sufficiently
demanding that a successful siting and demonstration at the selected site would be readily accepted at
most if at not all potential sites across the United States.
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The suitability criterion relates to the practicality and expense of conducting the demonstration at a
candidate site. Specifically, a suitable site should have all required facilities in place including a prov-
en landfill gas collection system, natural gas supply, permits, contracts for equipment and sale of elec-
tricity, and plenty of space available for the demonstration. Most importantly, the selected site should
have an excess supply of landfill gas available for the demonstration during the proposed period of the
demonstration gas pretreatment test in 1992 and the fuel cell demonstration in 1993.
2J.2.2 Characteristics of Candidate Sites and Selection
The candidate site selection was based upon the twelve active projects which Pacific Energy currently
manages, as shown in Table 2.3-8. A preliminary assessment conducted by Pacific Energy identified
four of these sites as potential candidates for the EPA demonstration. These sites are: the Oxnard
Station in Oxnard. California; the Penrose Station in Sun Valley, California; the Toyon Station in Los
Angeles, California; and the Otay Station in San Diego, California. Tables 2.3-9 and 2.3-10 show how
these four candidate sites were assessed against the detailed sub-criteria which were developed in the
program. The two leading candidate sites that emerged were Penrose and the Toyon Canyon site be-
cause of their close proximity to the Pacific Energy and Southern California Gas facilities, and their
location within the South Coast Air Quality Management District. Oxnard and Otay are less attrac-
tive due to their greater distance from Los Angeles, and lack of natural gas service.
The Toyon site was eliminated when it was determined that there was insufficient excess landfill gas
available year-round for the demonstration, particularly during the summer months. This left the Pen-
rose site as the best site for the demonstration.
The Penrose site is representative of U.S. landfills. Landfill gas is provided from four separate landfills
with typical levels of contaminants and gas heating value. This site is also regulated by the South Coast
Air Quality Management District which is nationally recognized for strict environmental regulations,
so that a successful demonstration in this area is likely to be accepted by other localities within the
United States.
Table 2J-8. Pacific Energy Landfill Gas Sites
Landfill Gas Projects
Upland Pwr Sta.
Oxnard Pwr. Sta.
Penrose Pwr. Sta.
Tbyon Pwr. Sta.
Glide Pwr. Sta.
Bakersfield Pwr. Sta.
Stockton Pwr. Sta.
Lompoc Pwr. Sta.
Crazy Horse Pwr. Sta.
Santa Clara Pwr. Sta.
Otay Pwr. Sta.
Bonsall Pwr. Sta.
Location
Upland
Oxnard
Sun Valley
Los Angeles
Rockville
Bakersfield
Stockton
Lornpoc
Salinas
Santa Clara
San Diego
San Diego
CA
CA
CA
CA
MD
CA
CA
CA
CA
CA
CA
CA
TVP«
Elec. Pwr.
Elec. Pwr.
Elec. Pwr.
Elec. Pwr.
Elec. Pwr.
Elec. Pwr.
Elec. Pwr.
Elec. Pwr.
Elec. Pwr.
Elec. Pwr.
Elec. Pwr.
Elec. Pwr.
MWe
0.6
3.7
9.3
9.3
3.0
1.8
0.8
0.6
1.4
1.5
1.9
JLS.
35.4
Power Pur-
chaser
SCE
SCE
SCE
SCE
PEPCO
PG&E
PG&E
PG&E
PG&E
PG&E
SDG&E
SDG&E
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International Fuel Cells
FCR-11900A
Table 23-9. Assessment of Candidate Sites vs. Evaluation Criteria
NT OF CAMHDATE SITES
VS.
EVALUATION CltTElIA
OTAT
OFTMU4.I
UA.LMHMJ
• OOT MIOT COTOTMCTTurr' »*V>
orrum*
•0%
4TO-MO
47*4
(SO470
(to
a,
< 1%
4»
•4%
< 1%
< 1*
02%
t«
44%
31*
21
112
1*0-474
110
1C-1M
14-J4
7-M
1C-M
H*t AVOTOT
1CAOMO
MffOMOT APCD
• 4UW
l.tuw
J 7MW
TOT
T«
TOT
TOT
(NOTt:
TOT
TOT
TOT
T«
TOT
TOT
TOT
TOT
OIT •• I-*.
1 DOTH
R«predue«4 tram
b*ct Bvaltabl* copy.
JLPi J»-»l
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Table 2.3-10. Supplemental Landfill Data for Candidate Sites
• Number of land-
fills serving site/
names
• Ownership of
Landfills
• Distance from
Downtown Los
Angeles
• Site Description
• Ownership of Pro-
posed Fuel Cell
Site
• Status of Landfills
-Open
(OyClosed (C)
Penrose
1. Penrose
IShelton Arleta
3. Bradley
4.Tuxford
1. Private
2. City of LA.
3. Private
4. Private
15 miles (northwest)
Sun Valley/Burbank
Old Industrial
1. Private Industrial
2. Pacific Energy
1. Penrose (C)
IShelton-Arleta(C)
3. Bradley (C)
4.TuJdbrd (C)
Toyon
LToyon
1. City of LA.
7 miles (northwest)
Griffith Park
Woods - View of
Mountains
L City of LA. Dept.
of Parks (Griffith)
LToyon (C)
Oxnard
I.Santa Clara
1 Ventura Coastal
3.Ballard
1. City of Oxnard
2. Sanitation Dist
3. Private
70 miles (west) City of
Oxnard
River. New Hotel,
Golf Clubhouse,
Homes
1. City of Oxnard
2. Ventura County
1. Santa Clara (C)
1 Ventura (C)
3.Bailard (O)
Otay
l.Otay
1. County of San
Diego
100 miles (south) City
of Chula Vista
Hills, Light Industrial
l
1. City of San Diego
LOtay (O)
The Penrose site is entirely suitable for the demonstration. All required facilities are already in place
including: a proven landfill gas collection system, natural gas supply permits, contracts for equipment
and saleable electricity, and more than adequate space available for the demonstration. With the re-
cent tie-in to a fourth landfill, there is an excess of landfill gas available to provide the 84 SCFM re-
quired for the demonstration. The site is readily accessible within a half-hour of the main facilities of
the Pacific Energy and Southern California Gas. Support facilities and personnel are already in place.
2.3.13 Description of Selected Site
A detailed description of the selected site is given in Figures 23-8 and 2.3-9. These figures, provided by
Pacific Energy, describe the location and description of the existing landfill gas to energy conversion
equipment which consists of five 9375 megawatt internal combustion engine generator sets. This site
presently produces 8.9 megawatts of net power to the electrical grid.
Figure 23-10 shows an aerial photograph of the Penrose Station which is located off Tujunga Avenue
along the edge of the Penrose landfill. Site potential locations for the demonstration are identified on
the aerial photograph. The relative merits of these will be assessed early in Phase II, prior to making a
final selection.
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International Fuel Cells
FCR-11900A
mClFK LIGHTING ENERGY SYSTEMS
LANDFILL GAS
TO ELECTRIC
POWER
Situated in Sun Valley, an indus-
trial-residential area in Los
Angeles San Fernando Valley, the
Penrose power station like its twin
at Toyon Canyon, began opera-
tion in 1985 as one of the world s
largest landfill gas-to-electric
power plants The gas from this
relatively deep landfill fuels five
'Clean Burn internal combustion
engines to produce a maximum
8.9 megawatts (MW) of electrical
power which is sold to Southern
California Edison This alternative
energy resource can serve the
electrical needs of an estimated
8.900 homes and help conserve
our natural energy resources by
saving the equivalent of up to
115.000 barrels of oil per year In
addition, the proiect produces
risk-free revenue for the city, pays
local, state and federal taxes and
provides environmental and
safety benefits by reducing gas
migration and surface gas
emissions.
Landfill Description
The Penrose sanitary landfill.
owned by Los Angeles By-Products.
inc.. contains an estimated 9 mil-
lion tons of non-hazardous munic-
ipal waste The landfill opened in
Penrose Power Station
Penrose Plant Supplies Alternative Energy
to Southern California Power Grid
Figure 2.3-8. Penrose Plant Supplies Alternative Energy to Southern California Power Grid
(Courtesy of Pacific Energy)
-41-
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b.st »v«il«bl»copy.
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International Fuel Cells
FCR-11900A
Landfill Gas to Electric Power
i960 and closed m 1983 It covers 72 acres
and has an average depth of 200 feet
making it one of the deepest of Pacific
Lighting Energy Systems (PLES) landfill
proiects The landfill is located about fifteen
miles northwest of downtown Los Angeles
in Sun Valley and one mile west of the
Golden State freeway (Route 5) at Penrose
Avenue
Power Station Description
The power station and gas collection sys-
tems were designed and developed
syndicated and are operated by PLES
Construction work was completed in 10
months and start up began in December
1985
The gas collection system consists of 85
wells, of which 55 are single pipe wells and
30 are duplex wells containing two pipes
The duplex wells recover gas from the
midpoint and bottom of the landfill Each
well pipe (4" or 6"pvc) is slotted on the bot-
tom third to recover the gas produced and
has a butterfly valve installed on lop to con-
trol gas flow The wells are interconnected
by a surface and subsurface pipeline sys-
tem which fuels the power station located in
the northeast corner of the site.
Within the station six 150 horsepower
motor-driven reciprocating compressors
draw the gas from the landfill and through a
Iwo-stage oil oath prefilter at 20" to 40" vac-
uum The gas from the compressors at
90-100 psig passes through a pulsation
dampener and two coalescing filters, and is
delivered to five 2.650 horsepower Cooper
Superior Clean Burn low NOx internal
combustion engines Each engine drives an
i 875 kW 4160 volt synchronous generator
Together the five generators produce a
maximum 94 MW of power of which about 5
to 10 percent is used internally with the
remaining power fed to a 4160 volt 34.500
volt step-up transformer The power pro-
duced is sold to Southern California Edison
under a 20-year contract
A three-man crew operates and main-
tains the station during the day and an auto-
Key Project Data
Project Location
Landtiii Name
Landfill Owner
Landfill Size
Landfill Depth
Tons m Place (Retusei
Number ot Gas Weils
NumDer ot
Engine-Generators
Tyne of Engines
Engine Sue
Gross Horsepower
1 5 engines)
Type of Generators
Generator Sue
Gross kW (5 Generators)
On-sitekWuse
NeihWtoGnd-
Power Purcnaser
Eauivaiem Homes Served
Barrels 01 Oil Saved Yr
Estimated Proieci Lite
Sun Vaney Ciry ot Los Angeies
Penrose Sanitary Lanflttii
LOS Angeies By-Products me
72 acres
i50to200teetiaveragei
9 million
85
5
Gas-tired internal combustion
2.650np
13. 250 ng
4 160 volts syncnronous
1 875 kW
9.375 hW
5ao to 10° o
8 900 kW (maximum)
Southern California Edison
8 900 I maximum
11$. 000 (maximum!
20 years
made control system operates and
monitors the station at night. A computer
system registers any operating shutdown
and signals the stations off-duty operating
crew via a dial-up system
Corporate Background
PLES develops and operates energy
projects throughout the United States
including district heating and cooling
plants and plants which produce electric
power using alternative energy resources
such as landfill gas. wastewood. geo-
thermal hot water, and hydropower
PLES is a wholly-owned subsidiary of
Pacific Lighting Corporation (NYSE). a
multi-billion dollar a year holding company
whose principal subsidiary is Southern
California Gas Company PLES continues
a 100-year corporate heritage of energy
service.
For additional information contact:
Pacific Lighting Energy Systems
6055 E Washington Boulevard
Commerce California 90040
1213)725-1139
Figure 2.3-9. Landfill Gas to Electric Power
(Courtesy of Pacific Energy)
-42-
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International Fuel Cells
F/gwre 2.5-JO. Fwe/ Ce// 5ite Qprto/w
(Courtesy of Pacific Energy)
-43-
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International Fuel Cells
FCR-11900A
PHASE II PLAN
The goal for this demonstration project is to demonstrate recovery of energy from landfill gas in an
economical and environmentally effective manner, using a commercial phosphoric acid fuel cell. In
the program we will determine the feasibility of using landfill methane as a commercial fuel cell fuel;
define the amount of pretreatment needed to render the LFG suitable for the fuel cell; and document
the emission characteristics of the fuel cell energy recovery system.
Phase I activities were focused on defining the critical issues impeding implementation of the commer-
cial concept and requiring resolution prior to conducting the demonstration. The issues can be catego-
rized as follows: Those related to the amount of pretreatment needed to render LFG suitable for use in
a fuel cell; and those related to achieving rated power in the commercial fuel cell with the dilute meth-
ane fuel.
Phase n program logic is shown in Figure 2.3-11. We plan to conduct two tasks, one to verify the Bio-
Gas pretreatment system renders LFG suitable for fuel cell use, and a second task to generate a site
specific design which includes modifications to the PC2S fuel cell to maximize its power output on
LFG.
PHASE II PROGRAM LOGIC
8UBTASK 2J
MIBTAM 2.1
VERIFY PRETnEATU EMT
OPERATION AT SITE
• DESCRIBE SITE •PEQFIC
PROCESS DEMON. DETAILED
ENOINEERINO OESION. AND
PRELIMINARY TEST PLAN
• ESTIMATE PHASE III COSTS
OUTPUT
OUTPUT
OUTPUT
-DOCUMENTED
PERFORMANCE
ANDOPEMBIUTY
OF PRETREATUENT
- DETAILED DEMO
TESTMSMM
- DETAILED COST
ESTIMATE FOR
PHASE 111
-PHASE II
REPORT TO
CM
11M641
•me?
Figure 2.3-11. Phase II Program Logic
Task 2.1 Verify Pretreatment System Operation
There are two objectives in Task 2.1. Our main focus will be to demonstrate that the performance and
operability of the LFG pretreatment system is suitable for operation with the PC25 fuel cell at Penrose.
A secondary objective is to verify the Bio-Gas System's ability to accommodate contaminant levels
from various landfill conditions. This is important to show the applicability of the pretreatment pro-
cess in the commercial concept.
The major milestone schedule for this task is shown in Figure 2.3-12. The initial activity is to complete
the design of pretreatment system and fabricate the demonstration hardware. Concurrently, IFC will
work with Pacific Energy to obtain all necessary permits pertaining to local fire, safety, and building
codes and state and local requirements for air, water and noise emissions. Upon receipt of the neces-
-------
International Fuel Cells
FCR-11900A
sary permits, we will prepare the site to receive the gas pretreatment system. These activities are
planned to be completed by February 1992.
MILESTONES FOR TASK 2.1
VERIFY PRETREATMENT OPERATION AT SITE
WORK ELEMENT
FABRICATE
PRETREATMENT
OBTAIN PERMITS
PREPARE SITE
INSTALL
PRETREATMENT
TEST AND QA PLANS
TEST
PRETREATMENT
MEASURE
CONTAMINANTS
ASSESS RESULTS
S
19
0
91
N
i
D
r
J
i
!
F
r
r
i
1
M
f
r
A
•••
M
i
i
MHMfl^MH
199
J
f
r
1
1
2
J
r
A
S
0
N
11MO-02
•11107
Figure 2.3-12. Task 2.1 Major Milestone Schedule
Quality Assurance and Test Plans will be prepared in February 1992 for the verification testing of the
Bio-Gas pretreatment system. The plans will be submitted to EPA for review and approval prior to
initiating the Pretreatment Unit Test.
Bio-Gas will install and check out the pretreatment system at the Penrose site. We will confirm that the
operation of all electrical, mechanical and control functions meet the design requirements. Bio-Gas
will then transfer operation of the system to Pacific Energy when the unit is checked out. Operating
and maintenance manuals for the pretreatment unit will be provided to Pacific Energy by Bio-Gas.
The verification test of the gas pretreatment unit will be conducted for up to 500 hours. During the test,
an overall mass and energy balance will be defined. Landfill gas analyses of the feed gas and output
will define the effectiveness of the pretreat unit to clean up the LFG. Emissions tests of flare exhaust
and condensate streams will confirm that design emission levels have been achieved. This testing will
include a performance challenge test which will determine the ability of the gas pretreatment system to
remove sulfur and halogenated compounds. We plan to dope the input landfill gas to simulate levels
representative of a worse case landfill contamination level. This test is intended to verify the ability of
the pretreatment unit to operate effectively in commercial concept.
-45-
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International Fuel Cells
FCR-11900A
IFC will assess the results of the performance and operability test to determine the impact on the dem-
onstration to be conducted in Phase HI. If contaminant levels are judged too high. IFC will consider
modifications to the pretreatment unit, the fuel cell or both to resolve the issue. Solutions will be pro-
posed to EPA for their consideration.
We anticipate the activities of this task will be competed by July 1,1992, IFC will provide a complete
description of the pretreatment system including operation and maintenance manuals to the EPA in a
Topical Report.
Task 2J Demonstration Test Site Specific Design
The objective of this effort is to define the site specific design for the Phase IE demonstration, and
estimate the cost of the demonstration phase of the program. A major focus of the design effort will be
on defining the modifications to the PC25 fuel cell which maximize power output on landfill gas at
minimum demonstration cost.
During Phase I. IFC identified modifications to the PC25 which would increase power output on land-
fill gas (see Section 2.3.1). Modifications which would yield an output power rating of approximately
140 kW are the basis of the proposed program, however, additional modifications which could yield
175 kW rated power output were identified. These additional modifications will be studied further to
assess the cost impact to the program and to judge the benefit to the demonstration. A complete list of
modifications to achieve 200 kW will be provided to EPA.
The major milestone schedule for Task 2.2 is provided in Figure 2.3-13. IFC will generate a detailed
engineering design of the demonstration test hardware at the selected site. A process design will estab-
lish the requirements for site facilities, gas supply, demonstration hardware, and electrical, mechani-
cal and thermal interfaces. From these requirements we will design the demonstration hardware, in-
stallation interfaces and demonstration test plan to accomplish the goals of the program.
An outline for the Q/A Plan and Test Plan required in Phase TH will be generated to enable an accurate
cost estimate of the Phase UJ effort. IFC, with input from Pacific Energy, TRC. and Southern Califor-
nia Gas Company, will prepare a detailed cost estimate for Phase m from the site specific design, the
Q/A Plan and Test Plan.
A Phase n Final Report will be prepared in October of 1992 describing the site specific design, the
proposed demonstration test and the anticipated costs. The report will be submitted for EPA approv-
al in November 1992.
-46-
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International Fuel Cells
FCR-11900A
MILESTONES FOR TASK 2.2
DEFINE SITE SPECIFIC DESIGN FOR DEMONSTRATION TEST
WORK ELEMENT
PROCESS DESIGN
SITE SPECIFIC
ENGINEERING
DESIGN
PHASE III TEST
AND QA PLAN
REQUIREMENTS
PHASE III
COST ESTIMATE
REPORT
EPA APPROVAL
s
19
O
>91
N
D
J
F
M
A
M
1£
J
T
|
192
J
Y
^mm^m
A
J
S
1
O
r
,
N
,
i
1IMO-M
• 13107
Figure 2.3-13. Task 2.2 Major Milestone Schedule
-47-
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ImenmionalFue. Cells FCR-11900A
References:
1. U.S. Federal Register, May 30,1991, Part m Environmental Protection Agency, 40 CFR Parts 51,
52 and 60; Standards of Performance for New Stationary Sources and Guidelines for Control of
Existing Sources; Municipal Solid Waste Landfills; Proposed Rule. Guideline and Notice of Pub-
lic Hearing.
2. Air Emissions from Municipal Solid Waste Landfills - Background Information for Proposed
Standards and Guidelines, EPA-450/3-90-011a (NTIS PB91-197061). March 1991, page 3-30.
3. Solid Waste & Power, "Will Gas-To-Energy Work at Your Landfill?," Greg Maxwell, June 1990,
p.44.
4. Air Emissions from Municipal Solid Waste Landfills - Background Information for Proposed
Standards and Guidelines. EPA-450/3-90-011a (NTIS PB9M97061). March 1991, page 3-23.
5. Ibid, Table 3-6 pages 3-25 through 3-28.
-48-
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International Fuel Cells FCR-11900A
APPENDIX A
LANDFILL GAS PRETREATMENT
SYSTEM COMPONENT SPECIFICATION
Al
-------
TXTLEi
LANDFILL GAS
PRETREATMENT SYSTEM
COMPONENT SPECIFICATION
REV LTP
—
AUTHOR
J.L. PRESTON
RELEASE NO.
D*lPLZ33
DATE
X-_ ^ _l>«
+2 -
I
DDUCT FILE ADDRESS.
PWE« PUWT/PRBSRAH
STSTEH d TAG MO.
PART NO.
DOCUMENT NO.
PC25/LANDF1LL
FPRS
L
PAGE
FCCS 5736
OF
NO. OQS4 REV 10-M
A2
IFT FORM OOSH. B.OI.01
-------
r
REVISION RECORD
(DASM NO.)
LTR
REL NO.
LTR
DESCRIPTION
FCFQRMNO.OOMA i/aa
ORIGINAL ISSUE
OOCMT. NO.
REVISION
A3
FCCS 5736
PAGE
5/15/91
-------
1.0 SCOPE AND DESCRIPTION:
This specification defines the requirements for a landfill gas pretreatment system (pretreatmeru
system) for an EPA landfill-gas-to-energy demonstration utilizing a commercially available 200kW fue
cell power plant. The pretreatment system will remove sulfur and halide contaminants, water, and
particulates present in raw landfill gas. Removal of the landfill gas diluents, including carbon dioxide,
nitrogen, and oxygen, are not required.
The pretreatment system shall include means for contaminant removal, on-site destruction of
contaminants removed from the system, delivery pressure regulation of pretreated landfill gas fuel to
the fuel cell power plant, and all controls. It is anticipated that the system will be a complete skid
mounted and truck-transportable unit designed for exposed weather installation and unattended
operation with safety controls to provide automatic shutdown. It is desirable to apply a process
operating at a pressure as close to atmospheric as possible.
2.0 APPLICABLE DOCUMENTS:
At the time of contract, the latest version of the applicable documents with any amendments shall
apply.
2.1 NATIONAL STANDARDS:
This system must be suitable for siting in an industrial setting in the city of Los Angeles. It therefore
must be designed and built to recognize industrial standards such as ANSI B31 Code for Pressure
Piping, ASME Boiler and Pressure Vessel Code, NFPA, FM, AGA and NEMA.
2.2 STATE AND LOCAL CODES:
City of Los Angeles Unified Building Code,
City of Los Angeles Electrical Code,
City of Los Angeles Bureau of Fire Prevention Code,
City of Los Angeles Health Department Code,
California State Industrial Code: Title 8,
South Coast Air Quality Management District. Rules & Specifications
OOCMT. NO.
FCCS 5736
REVISION
PAGE
FORM NO. 00548 i/«
A4
-------
3.0 REQUIREMENTS:
3.1 SUMMARY:
The gas pretreatment system will accept compressed raw landfill gas available at 80 to 95 psig from
an existing site supply and will supply clean landfill gas of an appropriate temperature, pressure,
humidity, and contaminant specification limit to the fuel cell on demand at a flow rate of up :o
120,000 standard cubic feet per day (5000 SCFH). The system will provide the functions of water
and particulate removal, contaminant removal, contaminant incineration, and supply pressure
regulation on an automatic basis once operation is initiated.
3.2 INTERFACES:
3.2.1
Input Gas
The landfill gas feed to the pretreatment system will be available at up to 84
SCFM (5000 SCFH) and will have the following nominal properties:
Temperature 80-100°F
Pressure 80-95 PSIG
CH4 42-50%
C02 38-48%
N2 10-20%
Oxygen at less than or equal to 1 %
Water vapor: saturated at nominal delivery conditions
Heating value 425-510 BTU/SCF on a higher heating value basis
Total non-methane organic compounds (NMOC) of 862 ppmv
For the pretreatment system design the total halides as chloride is 264 ppmv and
total sulfur of 42 ppmv. These values are based on two times the EPA average
compositional analysis for 48 quantifications at 23 different sites shown m
Appendix A. Detailed compositional analysis for these values is given in Appendix
B.
FORM NO. 005*8 1/86
DOCMT. NO.
FCCS 5736
REVISION
PAGE
A5
-------
3.2.2
Output Gas Requirements to Fuel Ceil Power Plant
Flow
Pressure
Temperature
Dew Point
Total Sulfur
Total Halides
Particulates
Min
0
4
30
—
—
—
—
Max
5000
14
130
20
3
3
Particulate r
Units
SCFH
Inches of Water
(Column W.C.)
°F
°F
PPMv
PPMv
Paniculate removal of 100% at 1 micron or larger and
98% removal at 0.4 microns or larger
3.2.3
Other Site Interfaces
Location: Los Angeles, CA
Site Services Available
~ Landfill Gas Supply
Electricity
- Natural Gas
- Water
- Other site services to be defined by Pretreatment System Supplier
3.3 OPERATING CONDITIONS:
3.3.1
3.3.2
Start-Up
The pretreatment system design should be compatible with eventual automatic
start-up. Manual start-up is acceptable for the demonstration program. Start-Up
Time: 1 shift.
Shutdown
Normal shutdown can be accomplished manually.
In the event of malfunction in the fuel pretreatment system, the pretreatment
system shall have provisions for automatic shutdown which protects the
pretreatment system and does not exceed any site emissions limitations.
DOCMT. NO.
FCCS 5736
REVISION
PAGE
IFC FORM NO. 00648 1/86
A6
-------
3.3.3 Normal Operation
The operation of the pretreatmem system shall not be linked with the fuel ceil
power plant except that it can accept a shutdown signal from the fuel cell power
plant. The pretreat system should be capable of checkout and operation without
the fuel cell. A landfill gas pipeline operating at subatmospheric pressure (10 to
60 inches W.C. vacuum) is available to accept pretreated landfill gas during trials
without the fuel cell.
3.4 PRESSURE REGULATION:
Provide to the fuel cell power plant on demand pretreated landfill gas at up to 120,000 SCFD
(5000 SCFH) on a continuous, and uninterrupted basis at a delivery pressure of 4 to 14" of
W.C. Pretreatmem system shall provide rapid flow response to changes in the fuel cell demand.
Delivery pressure shall not fall below 4" W.C. during increased demand from 0 to 5000 SCFH
in 15 seconds.
3.5 CONTAMINANT DISPOSAL:
The pretreatment system shall not collect and store hazardous contaminants on site for later
shipment off site. All contaminants regenerated from the pretreatment system shall be
disposed of on-site using an incinerator which shall preclude dioxin formation, and shall be
consistent with the current South Coast Air Quality Management District design specifications.
3.6 LIFE:
The pretreatment system adsorbents and absorbents shall be designed for a minimum life of 1
year. Quarterly filter replacement is allowable only if this can be accomplished without
shutdown of the unit. Active components (solenoid valves, pumps, etc.) may be serviced on
an annual basis.
3.7 PERMITTING:
The design specifications and stampings of the pretreatment system shall be consistent with
all national, state and local codes and regulations as listed in Section 2.
REVISION
^^^HH^^*^^^^^l^^M^BHH^^^^^H^^*V^i^^^^^M^^HBi^i^^i^^i^Mi^^^^M
I NO. 00548 1/86
DOCMT. NO.
FCCS 5736
PAGE 6
A7
-------
3.8 DESIGN AND CONSTRUCTION:
The pretreatment system shall be modular, self-contained, and skid mounted. Materials or
construction should be compatible with the operating environment and operating schedule to
insure a minimum of two years of uninterrupted service. The system shall be designed to
operate outdoors in the Los Angeles, California area.
3.9 DOCUMENTATION:
- Installation Manual and Drawings including Point of
Connection Interface Locations
— Operating Manual
— Overhaul and Maintenance Manual
- P&l Diagram
- Electrical Diagram
- Process Row Diagram
- Equipment Drawings
— Vendor Supplied Literature for Purchased Equipment
- Foundation Loading Calculation Document
4.0 QUALITY ASSURANCE:
4.1 QUALITY CONTROL SYSTEM:
The supplier shall have a Quality Control System that will ensure that parts are manufactureo
to the requirements of this specification. IFC reserves the right to review the supplier's system
prior to contract award and to inspect pans and witness tests during manufacture and prior to
shipment. IFC or its representatives will act as the authorized inspector required by ANSI B31
Codes for Pressure Piping.
4.2 TESTING:
All testing required by applicable codes (e.g., ASME Code vessel pressure testing) will be
identified upon completion of the design, including a 24 hour pneumatic static test at 100% of
rated pressure.
4.3 REPORTS:
All test and code required documentation will be provided to IFC prior to delivery of the
pretreatment system.
DOCMT. NO.
FCCS 5736
REVISION
PAGE
7
IFC PORM NO. 0064B 1/86
A8
-------
5.0 PREPARATION FOR DELIVERY: j
5.1 IDENTIFICATION: !
I
The pretreatment system shall have a metal identification plate attached with the following j
information at a minimum: :
LANDFILL GAS PRETREATMENT SYSTEM j
IFC FCCS-5736
- vendor part number
- vendor serial number
property of U.S. EPA under contract 68-D1-0008
6.0 APPENDICES:
A. Landfill Gas Contaminant Composition for Pretreatment System Design
B. EPA Average Landfill Gas Contaminant Composition Analysis
NO. 00648 1/88
OOCMT. NO.
FCCS 5736
REVISION
PAGE 3
A9
-------
International Fuel Cells pCR-11900A
APPENDIX B
GAS ANALYSES FROM PENROSE LANDFILL
Bl
-------
LAJiDFTTJ, ffftg OPERATING SCENARIES
Landfill Gas Flow Rates fscfml *
Run #1 - Penrose, Sheldon, Bradley Blend
Penrose * 1325 scfn
Sheldon - 403 scfm
Bradley - 1650 scfm
Run 12 - Penrose, Bradley Blend
Pehroae = 1525 scfm
Bradley - 1650 scfn
Run #3 - Penrose, Natural Gas Blend
Penrose - 1724 scfa
Natural Gas - 325 acfn
Run 44 - Ponrosa, Sheldon, Natural Gas Blend
Penroee - 1611 sofm
Sheldon - 544 scfa
Natural Gas - 155 scfffl
Run 15 - Penrose, Sheldon, Bradley, Natural Gas Blend
Penroee • 1611 scfm
Sheldon - 450 scfm
Bradley - 1650 scfm
Natural Gas - 195 scfa
* Operating scenarios ran at Penrose Power station on
5/31/91. Landfill gas blend sample taken for sulfur
compound analysis for each scenario.
R. Rolfe
6/11/91
B2
-------
ZALCO LABORATORIES, INC.
Analytical S. Consulting Services.
B.C. Analytical
1225 Powell Street
Effl.ryvUU, CA 94608
Attention: Scott Chestnut
Lab. No.: 027113_001
Received: Apr 10, 1991
Reported: Apr 10, 1991
Sample Descript
A
Components
Carbon Dioxide
Oxygen
Nitrogen
Carbon Monoxide
Methane
Ethane
Propane
IsoButane
N-Butane
IsoPentane
N-Pentane
H«xan*<+
lonQ«nro*r>;52 4/10/9
CHROMATOGRAFHIC ANALYSIS
Mole %
39.47S
.330
14.013
0.000
46.080
0.000
0.000
0.000
0.000
.097
o.ooo
.004
1
(I 1610 1 *
Wt \
60.175
365
13.597
0.000
25.606
0.000
0.000
0.000
0.000
.243
O.COC
.013
G.P.M.
0.000
0.000
0.000
.035
0.000
.007
Totals •
100.000
100.000
»
A
SPECIFIC GRAVITY IAir • 1)
SPECIFIC VOLUME, cu.ft./lb
GROSS CALORIFIC VALUE, BTU/cu.tt.
GROSS CALORIFIC VALUE, BTU/cu.f£.
GROSS CALORIFIC VALUZ, BTU/lb
NET CALORIFIC VALUE, BTU/cu.ft.
NET CALORIFIC VALUE, BTU/CU.ft.
COMPRESSIBILITY FACTOR '2' (60 F,l ATM)
* Water Saturated
**
Dry
.9989
'.3.12
471.52
6164.74
417.43
424.65
.9977
8 60 F, 14.73 p«l
Mary
Organ
Richard L. Pvun*r
Laboratory Director
,43O9 Armour Avenue Bokersfield. California S33OS.
fSOSl 3SS-O539 B3 FAX.(BQS1 39S-3OB9
-------
TORIES, INC,
Analytical S. Consulting Services,
(Jl
B.C. Analytical
1255 Powell Street
Emeryville, CA 94608
Attention: Scoll CheaUiuL
Lab, No.i 027113_003
Received: Apr 10; 1991
Reported* Apr 10; 1991
D«scr i jLion sBr*Jley Ifci 17
rHROMATOSKAPHIC ANALYSIS (Z 16101
Cumpun«nus Mole \ ML %
G.P.M
Carbon Dioxide
Oxyywn
Ni i.; uyen
C
(SOS) 395-0539
B4 FAX.(BG5) 395-3OB9
-------
ZALCO LABORATORIES, INC.
Analytical r
Laboratory Director
Armour Avenue Bakerafield, California 933OS.
(80S] 39S-O539 B5 FAX,[BOS] 335-3069
-------
ZALCO LABORATORIES, INC.
Analytical & Consulting Services.
B.C. Analytical
1225 Powell Street
Emeryville, CA 94608
Attention: Scott Chestnut
Lab. No.; 027113_007
Received: Apr 10, 1991
Reported; Apr 10, 1991
Sample DeacriutioirTTuxf urd 10^56
* CHROMATOGRAPHIC ANALYSIS
Components Mole \
Carbon Dioxide 33.090
Oxyyen . 577
Nitrogen £8. 250
Carbon Monoxide 0.000
Methane 38.054
Ethane 0.000
Propane 0.000
IsoButane 0.000
N-Butane 0.000
IsoPentane 0.000
N-P«ntar>« .Oil
Hexanea+ .019
To La la « iOO.OOO
SPECIFIC GRAVITY (Air • 1)
SPECIFIC VOLUME, cu.ft./lb
GROSS CALORIFIC VALUE, BTU/eu.fl.
* GROSS CALORIFIC VALUE, BTU/cu.fl.
* GROSS CALORIFIC VALUE, BTU/lb
NET CALORIFIC VALUE, BTU/cu.ft.
* NET CALORIFIC VALUE, BTU/cu.ft.
COMPRESSIBILITY FACTOR '2' (60 F, 3
(2 1610)
WL \
50.582
.641
27.487
0 .000
21.205
0.000
0,000
0.000
0.000
0.000
,027
.057
100.000
ATM)
A
G.P.M.
o.ooo
0.000
0.000
0.000
.004
. ooa
.012
.9953
13.16
3fl0.57
387.15
5093.56
342.70
34A.62
. 998?.
* Water Saturated
* *
Dry Ga* 9 60 7, 14.73
W. Benit
Superyiaor
&
Richard L. Pennwr
Laboratory Director
Armour Avenut
(SOS] 39S-OS33
Bakerafield. California 933OQ
B6 FAX.(SOS] 39S-3OS9
-------
Analytical Report
LOG NO: G91-04-168
Received: 09 APR 91
Hailed: APR 1 7 1991
Mr. Scott Cheanut
BC Analytical, Air Monitoring Program
2000 Povell Street
Emeryvill., California 94608
Project: 4798-11
REPORT OF ANALYTICAL RESULTS
NO SAMFU DESCRIPTION, VAPOR OR
16B-1 Penroae
SAMPLES
Page 1
OATS SAMPLED
.Prl.Poll, (BPA-8240)
te Analyzed 04/11/91
Lution Factor, Times 1 5
1,1-Triehloroethane, ppb <250
1,2,2-Tetrachloroethane, ppb <250
,2-Trlchloroetnane, ppb <230
-Dlchloroethane, ppb <230
•Olchloroethene, ppb <230
1-Dlchloroa thane, ppb <250
I-Dlchlorobeiuene, ppb
i-Diehloropropaat, ppb
1-Dichloro benzene, ppb
i-Olchlorobenzene, ppb <250
ailoroethylvlnylethtr, ppb <230
lexanone, ppb <250
it one, ppb <230
rolein, ppb
rylonitrila, ppb
JBodlchleronethane, ppb
saoaethane, ppb
uene, ppb 2000
ofonn, ppb <250
lorobenzene, ppb 1000
rbon Tetrachloride, ppb <220
04/12/91
5
<230
<250
<220
3300
220
04/12/91
5
<250
<230-
<250
3300
<250
<230
<230
<230
<250
<150
<220
<250
<250
<220
<220
<230
<220
<230
<250
<250
<2SO
<230
1400
<250
<2SO
<250
1200
<220
<250
<230
04/10/91
1
00
OO
OO
OO
OO
00
OO
OO
00
OO
00
OO
00
OO
00
OO
00
400
00
100
OO
04/10/91
1
00
OO
00
00
OO
OO
OO
OO
00.
00
00
OO
00
00
OO
OO
00
400
00
90
00
c<
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Analytical Report
LOG NO: G91-04-168
Rtcelvtd: 09 APR 91
Mr. Scott Chtsnut
BC Analytical, Air Monitoring Program
2000 Fovtll Str«et
Enaryvilla, California 94608
Project: 4798-11
-OG NO
REPORT OF ANALYTICAL RESULTS
SAMPLE DESCRIPTION, VAPOR OR AIR SAMPLES
Page 2
DATS SAMPLED
$4-168-1 Penra***^
34-168-2 Bradley- Sheldon
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04-168-4 Skeldbn-Pre-Chiller
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PABANBTSR (jC
Chloroathane, ppb
Chlorofora, ppb
Chlor one thane, ppb
Carbon Olsulfide, ppb
Dibroaochlorome thane, ppb
Staylbeazene, ppb
Freon 113* ppb
Methyl ethyl ketone, ppb
Methyl isoburyl ketone, ppb
Hethylene chloride, ppb
Scyrene, ppb
^Trichloroethene, ppb
-tlrlchlorofluoroae thane, ppb
Toluene, ppb
tTttrmchl-oroethene, ppb
Vinyl acetate, ppb
* Vinyl chloride, ppb
Total Xylene Isoaera, ppb
*ici«-l,2-Dlchloroethene, ppb
ci3-l,3-01chloropropene, ppb
trans- 1,2-Dichloroethene, ppb
tran»-l,3-Dichloropropene, ppb
Other Vol. Pri, Poll. (IPA-82AO)
AAf IVhe^ew ^4etf ia^kV
Clmdtlt. CA 91391
09 APR 91
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09 APR 91
09 APR 91
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09 APR 91
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Analytical Report
LOG NOi G91-04-168
Receiv«dt 09 APR 91
Mr. Scott Chesnut
BC Analytical, Air Monitoring Program
2000 Powell Stre«t
Emeryville, California 94608
REPORT OF ANALYTICAL RESULTS
Project: 4798-11
Page 3
JDG NO SAMPLE DESCRIPTION, VAPOR OR AIR SAMPL
Ift-lfiR-rt Toye^
4-168-7 TuxforV^
14-168-8 BUnx
ARAMSTZR
fol.Pri.Poll. (SPA-8240)
Date Analysed
Dilution Factor, Tines 1
1,1,1-Trichlo roe thane, ppb
1,1,2,2-Tttrachloroethace, ppb
1,1,2-Trichloroethane, ppb
1,1-Dichloroethane, ppb
1,1-Dlchloroethene, ppb
1,2-Dichloroe thane, ppb
1,2-Dlchlorobeniene, ppb
1,2-Dichloropropane, ppb
1,3-Dlchlorobtnzene, ppb
1,4-Dlchlorobenxene, ppb
2-ChloEoetnylvlnyleth«r, ppb
2-Hexanona, ppb
Acetone, ppb
Acrolein, ppb
Aery lonlt rile, ppb
Bronodlchlorome thane, ppb
Bromoaethane, ppb
Benzene, ppb
Bromofora, ppb
Calorobenaene, ppb
Carbon Tetracalorlde, ppb
Chloroe thane, ppb
Chloroform, ppb
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Analytical Report
LOG NO: G91-04-168
Received: 09 APR 91
LOG NO
Mr. Scott Cheanut
BC Analytical, Air Monitoring Prograa
2000 Povell Street
Baeryville, California 94608
REPORT OF ANALYTICAL RESULTS
SAMPLE DESCRIPTION, VAPOR OR AIR SAMPLES
, Laboratory Manager
Project: 4798-11
Page 4
DATE SAMPLED
04-168-6 Tovon
04-168-8 Blank "
PARAMETER
Chlorooe thane, ppb
Carbon DUulfide, ppb
Dibromochloroae thane, ppb
tSthylbenzene, ppb
Preon 113, ppb
Methyl ethyl ketone, ppb
Methyl isobutyl ketone, ppb
Hethylene chloride, ppb
Styrene, ppb
Trichloroethene, ppb
Trichlor of luo rone thane, ppb
Toluene, ppb
Tetrachloroethene, ppb
Vinyl acetate, ppb
> Vinyl chloride, ppb
Total Xylene Xsoaer*, ppb
Jtci«-l,2-Dlehloroethene, ppb
clj-l,3-Dichloropropen«, ppb
tran»-l,2-Dlchloroethene, ppb
tran»-l,3-Dichloropropene, ppb
OtherxQol.Pri.Poll. (IPA-8240)
04-168-6 (
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International Fuel Cells FCR-11900A
APPENDIX C
GAS PRETREATMENT SYSTEM
MASS AND ENERGY BALANCE
PRELIMINARY DESIGN CALCULATIONS
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