By Brian Kish and David Buck Study of the Utilization of Bio-Gas (Methane) for the Coors Brewing Company

Introduction  The Coors Bottling Plant has been operating in Elkton, VA since 1987  Coors products are brought to the facility by railcars  Then they are blended, finished and packaged  The plant is located between the Blue Ridge Mountains and the South Fork of the Shenandoah River  The plant is designated Class I pristine for Environmental Permitting Conditions

Introduction Arial picture of the Virginia Facility of the Coors Brewing Company, Shenandoah Bottling Plant.

Expansion at the Coors Plant  Due to the increase in demand for their product Coors is adding another bottle and another can line to their plant in Elkton, VA

Expansion at the Coors Plant  Expansion will also include upgrades to the wastewater treatment plant.  Such as a  Biogas Boiler  Bulk Volume Fermenter  Engine Driven Induction Generator  Activated Sludge Basin  Chlorine Contact Tank

Wastewater Treatment Plant Wastewater Treatment Plant

The Bulk Volume Fermenter  Needs to run at a minimum temperature of 31 o C for maximum efficiency.  In the winter the BVF drops below 31 o C resulting in lower treatment capacity.  Produces methane gas burned as waste.  Previous EPA regulations had prevented Coors from using the excess methane for energy.

The Biogas Boiler  On August 15, 2000, Coors Brewing Company received and amendment to their previous permit allowing the installation of a biogas boiler.  The biogas boiler was specifically approved to burn excess methane gas produced by the anaerobic bacteria in the BVF.  Used to maintain the temperature of the BVF at 31 o C in winter months  A 10 o C drop in temperature will result in a 30-50% reduction in efficiency and treatment capacity.

The Biogas Boiler

Installation of an Induction Generator  The remaining 3.66 million Btu/hr of surplus methane not used by the biogas boiler will be available to one or more induction generators.  The generator will be used to provide electricity for the waste water treatment plant.

Induction Generator Induction Generator

Regulation Involved in the Installation of the Induction Generator  Determining if the induction generator will require a permit.  Size of the generator  Fuel type  Emissions & emission levels  National Ambient Air Quality Standards (NAAQS)

Emission Rate Exemption Levels Carbon monoxide100 tons per year Nitrogen dioxide10 tons per year Sulfur dioxide10 tons per year Particulate matter (PM10)10 tons per year Volatile organic compounds 10 tons per year Lead0.6 tons per year

Determining Emissions Levels from Stack Tests  Stack tests were conducted by Jasper Tech Systems for the following  Hydrocarbons  Carbon Monoxide CO  Carbon Dioxide CO 2  Oxygen O 2  Nitrogen Oxides NO x

Determining Emissions Levels from Stack Tests  The Pollutants tested in the emissions test were given in percent by volume and part per million (ppm) by volume.  The total exhaust of each pollutant by volume had to be calculated in order to determine the total amount of emissions in tons per year.  This was then multiplied by the density to get the total emissions per year by weight  A single engine had an exhaust rate of 400 ft 3 /min.

Determining Total Engine Exhaust Per Year from the Emissions Test (example calculation)  Total emissions of pollutant per year by volume  = (400 ft 3 /min) (0.1025)(60 min/hr) (8760 hrs/yr) (8760 hrs/yr)  = X 10 7 ft 3 /yr Note: represents the fraction of CO 2 by volume.

 Density =    =144 P/R  144 = the number of square inches in a square foot  R= the Universal Gas Constant =1544/MW =1544/44 = =1544/44 =  P = pressure =14.7 psi  T = temperature in Rankine = 960 o R  R = 1544/MW = 1544/44 = = 1544/44 =   = (144 X 14.7)/(35.09 X 960) = lbs/ft 3 = lbs/ft 3

 Total emissions of pollutant per year by weight  = ( lls/ft 3 )(2.155 x 10 7 ft 3 /yr)  = 1.35 x 10 6 lbs/yr  = tons/yr

Determining Total Emissions Exhaust from EPA Data  Example Calculation using Sulfur Dioxide SO 2  (725 ft 3 /hr) x (1028 Btu/ft 3 ) / =.7453 mmBtu/hr  ( lb/mmBtu) x (.7453 mmBtu/hr) = lb/hr  ( lb/hr) x (8760 hr/yr) = lb/yr  ( lb/yr) / (2000 lb/ton) = tpy

Final Calculated Emission Rates and Emission Rate Limits for the Induction generator. PollutantEmission Rate Limit (tons/year) Calculated Emissions for a single cogeneration set (tons/year) Calculated Emissions (single) /Limit Calculated Emissions for two cogeneration sets (tons/year) Calculated Emissions (two) /Limit Carbon monoxide Nitrogen dioxide Sulfur dioxide Particulate matter (PM10) Volatile organic compounds Lead Total

Conclusion The emission rates for nitrogen dioxide exceed the exemption level listed in 9VAC E. Therefore, the installation of one or more generators would require a permit under 9VAC The emission rates for nitrogen dioxide exceed the exemption level listed in 9VAC E. Therefore, the installation of one or more generators would require a permit under 9VAC

Obtaining a Permit For the Induction Generator A form 7 is an application for an air permit for new and modified source permits and state operating permits A form 7 is an application for an air permit for new and modified source permits and state operating permits

Acknowledgements We would like to thank Warren Heidt for the opportunity to complete this project. We would also like to thank him for all of the help and guidance that he gave to us over the last three semesters. We would like to thank Warren Heidt for the opportunity to complete this project. We would also like to thank him for all of the help and guidance that he gave to us over the last three semesters.

Acknowledgements Cont. We would also like to thank Dr. Klevickis for all of her help putting this project together. She kept a close eye on us through these past three semesters and made sure that we stayed on the right track. We would also like to thank Dr. Klevickis for all of her help putting this project together. She kept a close eye on us through these past three semesters and made sure that we stayed on the right track.