One man’s waste is another man’s energy

  • March 06, 2011
  • ProSoft Technology, Inc.
  • Case Study

By Adrienne Lutovsky, ProSoft Technology - March, 2011 Renewable energy is the way of the future. We already see hydro power towers on river beds, wind farms on hillsides, and solar panels on rooftops. Now Granger Electric in Pennsylvania has perfected a way to produce biogas, or a gas fuel derived from the decay of organic matter, by extracting methane from decomposing landfill waste and supplying it to customers as an alternative “greenhouse” fuel. Unharnessed, methane is one of the most potent greenhouse gases, and is twenty-three times more potent than carbon dioxide. Granger’s Lancaster Landfill Gas Recovery Project uses wells to both oxygenate the waste mass—expediting the decomposition process—and to trap the raw biogas before it can escape into the atmosphere. Separators are then used to clean the gas by extracting methane from the remaining gas substance (composed of carbon dioxide and trace elements) for use as a natural gas alternative. The whole process creates a symbiotic eco-relationship between waste and energy by aiding in the waste degradation process, by repurposing methane that would have otherwise been emitted into the atmosphere, by providing a less expensive form of energy to the world, and by providing an alternative to less eco-friendly options. Biogas Distribution One of Granger’s biggest customers, a major international food supplier, located thirteen miles away uses the green energy as a natural gas substitute to power the boilers that keep its entire plant operating. Because the biogas supplied by Granger is approximately half the cost of natural gas, the customer is able to significantly decrease their power costs without much of an upfront investment. To utilize Granger’s biogas product the customer had to customize their boiler system, but that required little more than increasing pipe sizes and installing an alternate piping system to be used in lieu of their natural gas or fuel supply. “It’s just another supply link that has to be put in and retrofitted into the existing scheme of things. This cost is recouped quickly by the savings they receive from our program,” commented Joe DiFerdinando, the Electrical Engineer with Granger Electric. Monitoring Consumption The plant is relatively large and spread out, with metering panels located throughout the various buildings on site to track the amount of gas used. Inside each of the three panels is a Rockwell Automation® CompactLogixTM Ethernet Programmable Automation Controllers (PAC), which monitor gas flow variables to measure consumption at the facility. To connect Granger’s main facility to its customers, a T1 hardwired phone line is used. The next decision was how to link up the end of the phone line at the customer site to the three PACs. “Because the plants are so spread out, we opted to use wireless at those points to save on installation. We just needed to find a product that is robust and easy to implement,” commented DiFerdinando. ProSoft Technology’s water- and dust-tight 802.11abg Industrial HotspotTM radios (RLX-IHW-66) were selected. “We use CAT-5 cable and Power over Ethernet (PoE) for both power supply to the radio and communication between the radio and the PAC. PoE allows us to plug the radios right into our PACs, plus the casing allows them to be mounted outside without weather concerns,” said DiFerdinando. The Result: A Fully Automated System The T1 connection links the plant back to a master PAC in Granger’s main plant, which is constantly pulling meter data from the remote customer sites and feeding the information up the chain to corporate for billing. The bandwidth allows them to see things in real-time, and is entirely automated so there is no need to go onsite at the customer’s facility to collect meter information.

“The radios are great. They saved us on installation and simplified implementation. I would recommend them to anyone,” commented DiFerdinando, “and my ProSoft sales representative was incredibly helpful, involved in the process, and knowledgeable on the technology and application. He deserves kudos.” Benefits Granger is a carbon negative facility. They convert their own product onsite into electricity using an electrical generator to run their facility, so they are entirely self-sustained. The balance of remaining unused electricity is sold to the local utilities company, reducing dependency on fossil fuels. The food manufacturer can feel good too. By using repurposed methane, the highly potent greenhouse gas was not emitted into the atmosphere. But that’s not all. “Landfill-gas-to-energy is not just an environmentally responsible choice, it makes sense financially. The savings we are able to offer our customers can be enough to help companies stay in America,” comments Joe DiFerdinando. “Another one of our customers, one of the largest manufacturers of disposable dishware, was able to save enough money using our natural gas substitute to add a third shift during the week and schedule weekends into production. The extra shifts mean extra jobs. It’s a nice feeling.”

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