Biogas and Coal Mining Emissions Reduction

One of the by-products of anaerobic digestion in a sewage treatment plant is produced vapor from the digester tank. This relatively low BTU gas (typically 600-900 BTU/cu. ft.) is comprised primarily of 55% methane and 45% carbon dioxide (CO2). Sewage digestion takes place in an aqueous environment, therefore the gas is saturated with water when it comes off the system. HY-BON was instrumental in the development of a specialized compressor package for the capture and compression of these highly corrosive vapors.

Since that time, HY-BON, a Cimarron company, has provided integrated packages for wastewater treatment facilities across the United States and across the globe. HY-BON is a leader in wastewater gas recovery, and can offer standard packages or custom designed units to highly detailed customer specifications. With over 60 years’ experience in handling low pressure gas streams, HY-BON’s engineers can draw on experience from multiple industries to address the most challenging gas streams.

These wastewater compression packages typically incorporate the use of a rotary vane compressor to take these vapors from a pressure of 2-3” W.C. (1-2 oz) to 40 psig or less discharge pressure. These wastewater compressed vapors are sent to one of three systems where they are utilized for a beneficial purpose. One system involves natural gas burning generator sets to generate electricity to be used by the sewage treatment plant. The second system consists of a low-BTU fuel gas boiler system to generate steam for the sewage plant for heating purposes or to feed steam-powered turbines. The third beneficial use for the gas is to send it back to the bottom of the digester tank to be used to churn the sludge that collects on the bottom of the tanks.

Digester gas units must be constructed to combat the destructive effects of a saturated, high carbon dioxide (CO2) content gas stream. HY-BON’s units are equipped with stainless steel piping and valve trims to handle the corrosive nature of the gas. In addition, the units must be able to address the issue of removing the water vapor from the gas stream. We utilize a suction filtration system and a discharge liquid knockout system to handle the water content within the gas stream. Despite sophisticated controls, all HY-BON units are designed for ease of maintenance, and years of trouble-free service.

HY-BON’s digester gas experience includes several projects for various burroughs in New York, most notably the Bay Park WWTP, the Coney Island WWTP and the Cedar Creek WTP.  All of these projects were very successful.  The Coney Island project was particularly notable as the gas from the digesters was routed to generator sets that actually produce electricity for the famous amusement park located on Coney Island.

For years HY-BON packaged the digester gas compressors that were labeled as the “FMC CRP Packages”.  This was a proprietary design by FMC (that was later sold to US Filter) that became the industry standard in low volume digester gas compression for a number of years.

HY-BON has also had successful projects for Infilco Degremont in Virginia, US Filter in Alabama and in several other states and the Pima County WWTP outside of Tucson, Arizona.

HY-BON Engineering has extensive experience capturing methane emissions from brewery operations. The methane gas produced by the fermentation process is captured and directed to electric generators. These electric generators are then utilized to provide power for a significant percentage of the brewery. HY-BON has successfully implemented Biogas capture in many breweries in North and South America. Customers include Miller Brewing, Modelo, Corona, and Tecate.

The vapor recovery unit (VRU) pictured below is utilizing rotary vane compressors to capture approximately 1100 mcfd at a discharge pressure of 40 psig. High concentrations of carbon dioxide (CO2) and water in this Biogas application combine to produce carbonic acid, adding a unique level of sophistication to the package specifications.

Footprint requirements were minimal on this application due to the existing infrastructure of the brewery facility. The methane gas captured from the brewing process was piped across the facility and used to power electric generators – supplying power to the brewery.

Every landfill gas operator in the U.S. is now faced with addressing the issue of the gas produced by the landfill (LFG) during the decomposition of organic matter residing in the landfill. The U.S. Environmental Protection Agency has determined that this landfill gas (LFG) must be collected and may no longer be vented to the atmosphere.
Landfill gas is typically composed of 55% methane and 45% carbon dioxide (CO2). Landfill gas (LFG) is wet in nature and therefore quite corrosive. Most landfills give this gas up rather reluctantly, with pressures of 1-2” W.C. being quite common. The majority of landfills in North America have already been required to install a gas gathering system to collect the LFG rather than allowing it to vent to the atmosphere. Typically this collection system consists of wells bored into the closed sections of the landfill to relieve the landfill gas (LFG) pressure and to flow this gas to a manifolded system. HY-BON’s compressor systems collect this landfill gas (LFG) from the manifold and compress it to be used for any of several beneficial uses.
Landfill gas may be utilized in its “raw” form to power natural gas burning engine-driven generator packages. These systems create electricity from the LFG to be used to supplement onsite electrical needs or sold into the power grid. Other landfill gas systems are in place in which the operator actually cleans up the LFG, through membrane systems, chemical systems or pressure-swing absorption systems, to pipeline grade quality.
Dependent upon the beneficial use for the LFG, HY-BON designs and builds compression systems to handle the operator’s needs. These systems can range from low pressure, single-stage units to medium pressure two- or three-stage systems. HY-BON equipment can be designed to handle a variety of gas streams, as well as the most sophisticated customer specifications.

The Momentum Biogas series of elevated flares is our most economical line of combustion equipment for the biogas sector, offering a cost-effective solution with rapid delivery.

Momentum flares utilize a specially designed “burner and shroud” system to manage the intricate mixing with ambient air to provide a high DRE (98%) and high turndown ratio in a simple, yet effective, product.

The Momentum Series is a reliable method of emission control and can become part of a customized system tailored to fit your location. These elevated flares are easy to install and can handle the toughest environmental conditions.

Key features when considering Cimarron’s MOMENTUM Biogas Series flares:

• Economical flare package
• 100% stainless steel construction for long service life and low maintenance cost
• Profire ignition system with intergraded BMS (burner management system)
• High turndown ratio
• Advanced designed stainless steel windshield provide optimal flame stability even at minimum flow rates
• Oversized stainless steel base plate for a quick, easy and cost-effective erection
• Guywire supported
• 98% DRE (destruction and removal efficiency)
• Optional flame deflagration arrester
• Optional solar-powered 12-volt ignition system
• Commissioning and start-up support from our in-house service team 24/7/365

Cimarron’s enclosed biogas flares are a simple and cost effective combustion solution for a variety of applications where a hidden flame is required.

The superior design, high quality stainless steel construction and unmatched versatility make the enclosed flares an exceptional choice for emissions control within the biogas and wastewater industries. Additionally, each product within our Enclosed Flare line is able to perform under the harshest environmental conditions.

Because each enclosed flare can be further customized with available options, users are ensured a system that meets their specific requirements. Cimarron’s enclosed ground flares meet or exceed the most stringent destruction efficiency standards. Our products are designed with automatic starting and stopping features and operate under a wide range of waste gas flows with no visible flame. Made entirely of stainless steel, these enclosed ground flares will provide the operator years of mechanical integrity (versus carbon steel alternatives) and a clean, rust-free look at your facility.

Biogas Enclosed Ground Flares Standard Products:

• Biogas AB-20 (20” Diameter by 12’ in Height) up to 2.4 MMBTU/HR
• Biogas AB-100 (33” Diameter by 16’ in Height) up to 9.2 MMBTU/HR
• Biogas AB-200 (47” Diameter by 20’ in Height) up to 18.4 MMBTU/HR
• Biogas HTF-0.5 (24” Diameter by 21’ Height, Base Frame ~4’ X 4’) up to 1.7 MMBTU/HR
• Biogas HTF-1.0 (26” Diameter by 30’ in Height, Base Frame ~5’ X 5’) up to 3.4 MMBTU/HR
• Biogas HTF-3.5 (46” Diameter by 35’ in Height, Base Frame ~5’ X 5’) up to 11.9 MMBTU/HR

Key Features when considering Cimarron’s biogas enclosed ground flares:

• Small footprint, requiring minimum plot space
• Scalable flow rates from 0-18.4 MMBTU/HR
• 100% stainless steel construction for long service life and low maintenance cost
• AB Series is the most economical enclosed ground flare in the industry (heat capacity per square inch)
• Ignition system and continuous pilot with BMS (burner management system)
• Self Supported Design
• High turndown ratio
• Low operating cost
• HTF Series is refractory lined and temperature controlled
• HTF Series is low NOx performance (less than .012 lb/MMBTU)
• 99% DRE (destruction and removal efficiency) on HTF
• SCADA integration with control panel for remote monitoring
• Optional flame deflagration arrester
• Optional solar-powered 12-volt ignition system
• BMS with standard remote start/stop capabilities
• Installation supervision
• Commissioning and start-up support from our in-house service team 24/7/365