BIOFUEL POWER GENERATION SYSTEMS

• US 20170184015A1
• Filed: 12/30/2014
• Published: 06/29/2017
• Est. Priority Date: 04/28/2014
• Status: Abandoned Application

• Current Assignee: Kohler Company
• Original Assignee: Kohler Company
• Inventors: Andren, Travis J., Garrels, Clayton C., Rumao, Manuel, Hudak, Eric B.
• Application Number:
  US15/301,997
• Publication Number:
  US 20170184015A1
• Time in Patent Office: Days
• CPC Class Codes: B01J 19/24 Stationary reactors without moving elements inside B01J19/08, B01J19/26 take precedence; with stationary particles B01J8/02
• CPC Class Codes: B01J 2219/00049 Controlling or regulating processes
• CPC Class Codes: B01J 2219/24 Stationary reactors without moving elements inside
• CPC Class Codes: C12M 21/04 for producing gas, e.g. biogas digesters for manure with production of biogas A01C3/028, biological treatment of water, waste water or sewage C02F3/00, C02F11/02, preparation of natural gas or syngas C10L3/06, C10L3/10
• CPC Class Codes: C12M 23/36 Means for collection or storage of gas; Gas holders
• CPC Class Codes: C12M 23/44 Multiple separable units; Modules
• CPC Class Codes: C12M 43/08 Bioreactors or fermenters combined with devices or plants for production of electricity
• CPC Class Codes: F02B 43/08 Plants characterised by the engines using gaseous fuel generated in the plant from solid fuel, e.g. wood
• CPC Class Codes: F02B 63/04 for electric generators
• CPC Class Codes: F02M 21/0215 Mixtures of gaseous fuels; Natural gas; Biogas; Mine gas; Landfill gas
• CPC Class Codes: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04
• CPC Class Codes: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02P 80/20 using renewable energy
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels

Abstract

An integrated modular biomass to electric power generation system is disclosed. The system comprises various subsystem modules including components which may be prefabricated and mounted on separate and portable self-supporting liftable platforms in a factory controlled environment. The modules may include biomass to biofuel conversion and refinement process related modules and power generation modules. The modules may be transported from the factory to a power generation site, which in some non-limiting examples may comprise part of an agricultural or farming site that produces animal and/or agricultural wastes which may be converted to biofuel. The modules are positioned on site and fluidly coupled together to form a complete biofuel powered electric generation system. A plurality of standardized size subsystem modules of several different process or electrical capacities may be provided for selection to form the complete system. The system may include a biogas production process, biodiesel production process, or both.

Claims

1. A modular integrated biofuel power generation system comprising:

a digester subsystem module including a digester configured to convert biomass into biogas; and

an electric power generation subsystem module including an internal combustion engine and electrical generator configured for generating electricity, the internal combustion engine fluidly coupled to and configured to burn the biogas produced by the digester;

the components of each module being mounted on individual self-supporting and transportable structural platforms;

Wherein the modules are fluidly coupled together on a power generation site after placement of each module.

2. The system of claim 1, wherein fluid and electrical interconnection between components in each module are made in a controlled factory environment before shipment of the modules to the site.

3. The system of claim 1, further comprising a waste heat recovery system configured to capture heat generated by the internal combustion engine of the power generation subsystem module.

4. The system of claim 3, wherein the waste heat recovery system includes an insulated flow loop or path configured to transfer a heated working fluid from the power generation subsystem module to the digester subsystem module for heating the digester.

5. The system of claim 4, wherein the waste heat recovery system is a once-through hot air type system including a blower.

6. The system of claim 4, wherein the waste heat recovery system is a recirculating coolant type system including a pump.

7. The system of claim 3, wherein the waste heat recovery system is configured to extract heat from combustion gases generated by the internal combustion engine.

8. The system of claim 7, wherein the platforms of the modules are configured to fit onto a flatbed truck for transport

9. The system of claim 1, further comprising a self-supporting biogas treatment subsystem module interconnected on site between the digester subsystem module and the power generation subsystem module.

10. The system of claim 1, further comprising a self-supporting biogas storage subsystem module interconnected on site between the digester subsystem module and the power generation subsystem module.

11. The system of claim 1, further comprising a self-supporting central system controller subsystem module operably interconnected to the power generation and digester subsystem modules, the controller subsystem module controlling operation of the digester and the internal combustion engine.

12. The system of claim 1, wherein the internal combustion engine is configured to burn fuel from an alternate non-biogas fuel source.

13. The system of claim 12, wherein the internal combustion engine is dual fuel engine configured to burn biogas and liquid biodiesel fuels.

14. The system of claim 1, wherein the biomass comprises manure.

15. A modular integrated biofuel power generation system comprising

a filter/treatment subsystem module configured to convert raw oils and fats into biodiesel via a chemical reaction;

a cleaner/refining subsystem module configured to purify the biodiesel by removing byproducts of the chemical reaction; and

a power generation subsystem module including an internal combustion engine and electrical generator configured for generating electricity, the internal combustion engine fluidly coupled to and configured to burn the biodiesel produced by the system;

the components of each module being mounted on an individual self-supporting and transportable structural platforms;

wherein the modules are fluidly coupled together on a power generation site after placement of each module.

16. The system of claim 15, further comprising a self-supporting biodiesel storage module interconnected on site between the cleaner/refining subsystem module and the power generation subsystem module.

17. The system of claim 15, further comprising a self-supporting central system controller subsystem module operably interconnected to the power generation and filter/treatment subsystem modules, the controller subsystem module controlling operation of the filter/treatment and the internal combustion engine.

18. The system of claim 15, wherein the internal combustion engine is dual fuel engine configured to burn biogas and liquid biodiesel fuels.

19. A method for forming a modular integrated biofuel power generation system comprising:

selecting a factory prefabricated self-supporting first digester subsystem module having a first capacity from a plurality of prefabricated self-supporting digester subsystem modules each having a different capacity, the first digester subsystem module including a digester configured to convert biomass into biogas, wherein the first digester subsystem module comprises a transportable structural equipment platform configured to be lifted as a single unit;

selecting a factory prefabricated self-supporting first biogas treatment subsystem module having a first capacity from a plurality of prefabricated self-supporting biogas treatment subsystem modules each having a different capacity the first biogas treatment subsystem module configured to refine the biogas produced by the digester, wherein the first biogas treatment subsystem module comprises a transportable structural equipment platform configured to be lifted as a single unit;

selecting a factory prefabricated self-supporting first electric power generation subsystem module haying a first electrical output rating from a plurality of prefabricated self-supporting power generation subsystem modules each having a different electrical output rating, the first electric power generation subsystem module including an internal combustion engine and electrical generator configured for generating electricity, wherein the first power generation subsystem module comprises a transportable structural equipment platform configured to be lifted as a single unit;

transporting the first digester subsystem module, first biogas treatment subsystem module, and first electric power generation subsystem module from a factory to a remote power generation site location;

emplacing the first digester subsystem module, first biogas treatment subsystem module, and first electric power generation subsystem module at the power generation site;

fluidly coupling the digester to the first biogas treatment subsystem module via a field run flow conduit; and

fluidly coupling the internal combustion engine to the first biogas treatment subsystem module via a field run flow conduit.

20. The method of claim 19, further comprising;

a waste heat recovery system configured to capture heat generated by the internal combustion engine of the power generation subsystem module; and

installing an insulated flow loop or path at the power generation site configured to transfer a heated working fluid from the first power generation subsystem module to the first digester subsystem module for heating the digester.