Frequently Asked Questions About the BioMax®

What is a BioMax®?

BioMax® is the registered trade name used by Community Power Corporation for its family of power systems that convert biomass energy to thermal and/or electrical power.

The current pre-commercial BioMax® power system converts a number of different biomass fuels to a maximum of 15 kWe, either single or three-phase utility-grade power. We have a 5 kW system under field test, and are developing both a 25 and 50 kWe system

What is biomass energy?

Biomass energy is a form of solar energy that is released when the stored energy of sunlight is converted to energy. About 1% of the solar energy striking a plant is stored as energy through the photosynthesis process. When the chemical bonds between adjacent carbon, hydrogen, and oxygen molecules are broken by digestion, combustion, or decomposition these substances release stored energy.

The biomass resource is made available on a renewable basis through natural processes, or it can be made available as a byproduct of human activities. According to the Michigan Biomass Energy Program, “biomass resources are quite significant, as approximately 100 terawatt-years of chemical energy are stored in plants each year (an amount of energy equivalent to ten times that of humanity's current energy needs).”

What types of biomass resources will the BioMax® convert to usable energy?

The BioMax® is designed to use a number of residues from the agricultural and forest industries.

To date, we have converted the following biomass resources to electricity and heat: commercial pellets made from sawdust and peanut shells, coconut shells, wood chips, corn, soybeans, pecan shells, coffee husks, chicken litter and nutmeg shells.

We have also begun the experimentation of co-firing biomass with waste streams from micro-factories. These waste streams include leather, nylon, rubber, cotton, denim, etc.

To the best of our knowledge, CPC is the world’s first company to convert military dry packaging waste to heat and power. These materials include paper, cardboard, fiberboard, and some plastics.

What are the factors contributing to a good biomass resource?

A good biomass resource has the following characteristics:

Available in large quantity to assure long-term sustainability

Low moisture content

Dense

Small size, able to flow well

Low ash content

Low/no cost, not subject to large price swings

Available locally, not requiring shipment long distances

Non-toxic, able to be handled by humans

As a rule-of-thumb, woody types of biomass are good fuel. These include wood chips, manufactured pellets, and many kinds of nutshells. Some of the heavier paper products are also good. Light, low-density fuels such as grasses; fuels with high silicon content such as rice husks; and fuels with high moisture content such as bagasse are more difficult to use as fuel.

Why was the BioMax® developed?

We believe the BioMax® is an ideal technology for the distributed generation market. CPC is a leader in the electrification of rural communities using renewable energy, however we have noted the abundance of biomass and the minimal use of it for modern energy purposes

The US Department of Energy issued a Phase one contract to CPC in March 1998 to conduct a market assessment of a Small Modular Biopower (SMB) system in the range of 5kW to 5 MW. A key requirement of the program was the desire for a standard power system with the potential for high volume manufacture. Of 35 bidders, CPC was one a successful bidder for this phase one and assessed the requirements for electrification of off-grid communities using an SMB in three countries (Philippines, Brazil and Indonesia).

CPC was one of four companies to be awarded a phase 2a SMB contract in November 1999 to develop and demonstrate a 12 ½ kWe prototype in the Philippines with its partner Shell Renewables.

We were the first of the four phase 2 companies to receive a follow-on phase 2b contract to perform expanded field verification tests prior to commercialization, and the first of the four companies to field a pre-commercial unit.

The SMB project has been completed with all major milestones successfully achieved.

What is unique about the BioMax®

The BioMax® is the state of the art in highly automated small modular biopower systems. A unique aspect of the BioMax® is the way it is configured. We refer to this as our Integrated Modular Architecture concept wherein the system is composed of modules that can be easily integrated.

The first module is the Drier/Feeder Module that not only provides the biomass to the gasifier, but dries the biomass using waste heat from the gasification process.

The second module is the Gas Production Module that uses a downdraft gasifier to convert the biomass to a gas that can be cooled and cleaned prior to being consumed. The gas can be used to make electricity, electricity and heat, heat, shaft power, or liquid fuels.

The final module is the Power Production Module that converts the chemical energy of the producer gas to electricity. In the current generation of systems, we use an internal combustion engine generator set, because they are sold world-wide in volume. Other prime movers are candidates for integration with the Gas Production Module. These include a stirling engine, fuel cell and microturbine.

What are some of the features of the BioMax®?

The following is a partial list of features of the phase 2b 15 kW systems:

Fully automated start-up, operation and shutdown.

Follow loads in a ratio of 10:1 from peak to base.

Inherently low production of tars and particulates.

Low NOx and SOx

Uses locally available biomass residues to

i. Displace higher priced fossil fuels, both gaseous and liquid

ii. Reduce greenhouse gas emissions

iii. Create markets for otherwise waste materials

Generates heat that can be used for productive uses or for residential heating applications

Modular, able to be paralleled with other power systems including other BioMax® systems.

Mobile, able to be quickly installed and relocated

Small footprint

Able to be manufactured in most countries of the world using locally available components

Can operate in a dual fuel mode --- biomass and a fossil fuel, either one at a time or both together.

Lower capital cost than an equivalent energy PV/diesel or a Wind/diesel hybrid where the average wind speed is less than 5 M/sec

Meets World Bank environmental requirements for biomass systems

Adaptable to a range of prime movers such as internal engines, stirling engines, micro-turbines and fuel cells.

How does the BioMax® generate electricity?

The heart of the BioMax® is a downdraft gasifier that converts biomass to a low BTU (120 – 160 BTU/cubic foot) producer gas, a mixture of fuel gases such as hydrogen, carbon monoxide and methane. Producer gas is converted to electricity as follows:

Internal combustion engine: gas is ignited in cylinder and crankshaft spins an electrical generator.

Stirling engine: gas is combusted in a radiant burner that heats the head and transfers heat to an internal working fluid for conversion to electricity via a linear alternator.

Micro-turbine*: gas is combusted in a turbine and converted to AC electricity via a power conditioning system

Fuel cell: gas constituents are chemically combined in the fuel cell to create electricity.

*While CPC has successfully operated both an internal combustion and a stirling engine, we have yet to apply BioMax® technology to a micro-turbine.

Is the BioMax® safe to operate?

Yes. Explosions are prevented by using rupture disks to prevent dangerous pressures from building up in case of premature gas ignition. We also do not accumulate large volumes of producer gas. Design features prevent fires. Operators are trained and provided with proper equipment.

What is its operating efficiency?

Target electrical efficiencies vary by the choice of prime mover as follows:

Internal combustion: 15-30% (we have achieved 25% to date)

Stirling engine: 5-25%

Micro-turbine: 10-20%

Fuel cell: 25-45%

When the waste heat can be used in a combined heat and power mode, the overall efficiency can be greater than 80 %.

A larger system, rated at 50 kWe, is currently being testing with electrical efficiencies of at least 25%. With the use of higher compression ratios, and available control technologies we believe it is possible to achieve electrical efficiencies greater than or equal to 30%.

What happens with the heat that is generated?

In a straight electrical application, the heat is not used. In a combined heat and power mode, a significant fraction of the heat is captured for use elsewhere. Heat is typically captured through the use of a conventional heat exchanger. Maximum economic value is received if the biomass is free and the heat is used to displace thermal energy from high priced natural gas or propane.

What are the waste products and emissions of the BioMax®?

The BioMax® uses a dry system to cool and clean the producer gas therefore eliminating the need to process large quantities of contaminated water as found in wet scrubbers.

Solids collected are processed as follows:

Ash and char – stored and periodically combusted to ash that can be dispersed in the soil as an amendment

Tars and soot – recycled back through the gasifier

Expended filters – stored and periodically combusted

Solid emissions are non-hazardous.

Gaseous emissions meet CARB standards for 2003.

Who are likely customers of the BioMax®?

There are many groups that will benefit from the use of the BioMax®. The groups are distinguished by their objectives.

1. Sell energy services: These customers will own and operate the power system and provide electrical and/or thermal energy to their customers and be paid based upon the number of kWh delivered. Example: Energy Service Company.

2. Displace other fuels. Typically these customers will have access to biomass fuel that is significantly lower cost than existing fossil fuel or electricity. Example: Greenhouse owner that is able to displace natural gas.

3. Develop alternate uses for biomass: These customers will have access to an abundance of biomass and will be looking to develop applications for its use either as a source of revenue or to avoid other costs. Example: Forest Service desire to reduce forest fuel loading that could otherwise lead to degradation of forest health or increase the potential of forest fires.

4. Disaster relief: Typically after certain natural disasters there is an abundance of biomass in the form of downed trees and construction waste. In addition power lines may be cut so that there is the potential that the biomass could be used to generate large amounts of AC power. In addition, waste heat may also be generated to sterilize water.

5. Avoid disposal costs: Customers in this category will be able to use the biomass to minimize costs that might result from rules and regulations that affect the disposal of biomass. Example: convert wood pallets to on-site energy as opposed to shipping to a distant landfill.

6. Self-generation of heat and power: Use biomass to provide both electrical and thermal energy to captive operations. Often, this energy displaces higher priced electricity and/or propane/natural gas. Example: Small processing plant, such as a grain mill that produces biomass waste that could be used for powering equipment and drying the grain.

7. Educate potential users: Use a small, portable biopower system as an educational tool. Example: Trailer mounted system that a Biomass Energy Agency could use to educate regional stakeholders.

8. Research the feasibility of biopower: Perform pilot experiments on a lab-based biopower system to become familiar with the technology and to determine its feasibility for deployment in a particular application. Example: Research organization within a university, utility or energy service company.

Can the output capacity of the BioMax® be scaled up or down from the current size?

Yes. The key is the size of the prime mover. We have developed a 5 kW system and a 50 kW system using the 15 kW technology as the basis. The maximum size distributed energy system we have targeted is 500 kW.

Is there a large market for small modular biopower?

The BioMax® is designed to compete against engine generators, renewable systems such as Photovoltaics and Wind, and propane.

Typical future commercial customers: US Army; Small wood-working companies; Nut and tree fruit processing companies; Buildings/greenhouses with gas-fired boilers; Lumber processing/drying companies currently using natural gas/propane; Off-grid Homeowners; Utilities; Farms and Farmer cooperatives; and Biofuels research organizations. Most of the future customers have the potential to accumulate biomass residues on-site, thereby eliminating collection and transportation costs.

The Energy Generation Systems Association reports that global annual sales of diesel engines less than 200 kVA exceed 300,000 units with a total market value of nearly $10B.

Is the BioMax® complicated to operate?

No, primarily due to the fully automated feature of the BioMax®. However, it does require training in the operation, maintenance, and health and safety requirements.

Anyone who is qualified to operate a diesel engine could operate a BioMax®.

Does the BioMax® require a full-time operator?

No, but there are a variety of tasks involved mainly with the feedstock supply and maintenance that require regular operator intervention.

Can the BioMax® run continuously?

The 15 kW system was designed for batch rather than continuous operation, however, our 50 kW system is designed to operate 24 hours per day, 6 days per week.

The longest that the current pre-commercial 15 kW system has been operated at full power, on 100% biomass, to date is 100 hours, and 149 hours for the 50 kW system.

The need for continuous operation increases with system size. For the very smallest BioMax® systems, most applications require intermittent power on the order of 3 to 8 hours per day.

Can the BioMax® be connected to a utility grid?

Yes, two systems have been interconnected with the California grid. One was a 12 ½ kW system, and the other a 15 kW system.

If not providing power to the grid, the power can be used on-site, and displace electricity at its retail value. In most states, delivering power into the grid is priced at a lower wholesale value. In a state allowing net metering of small biopower the user would receive credit for the power at its retail rate.

Is the BioMax® a commercial product?

At this stage it is a pre-commercial product that was developed to confirm its feasibility for application to both domestic and international markets. As a result of field tests conducted in an extensive product validation program, we have identified a variety of improvements that are being incorporated in the new BioMax® 25 and BioMax® 50 prior to their commercial sale.

When will it be commercial?

We have sold several systems on a commercial basis, however, large scale commercialization will require investment capital that we expect as early as 2006.

Where will it be manufactured?

That remains to be determined, however, we expect to have manufacturing operations in North America, Asia, Latin America and Europe at a minimum. We have begun limited manufacturing of complete modules at two different manufacturing locations in the US.

How much does the BioMax® cost?

For current versions of the pre-commercial BioMax®, contact CPC to determine the cost of a system meeting your needs. For the commercial system, cost will be a function of the prime mover, capacity, location, fuel used, and quantity. For internal combustion-based systems our long-range, commercial target cost is to produce systems for sale between $700/kW and $5,000/kW.

Is the BioMax® cost effective?

Yes, but one would have to perform an analysis looking at their particular situation. The analysis should take into account such parameters as the intended application, installed capital cost, operating cost (mainly labor and fuel cost), hrs of daily operation, peak load and daily energy requirement.

The best economics will occur when the user has high priced conventional energy (electricity and natural gas for example), where the user has a biomass supply on-hand, and where there is a need for both heat and power. If the user pays to dispose of the biomass, then the economics can be extremely favorable.

What are the competing technologies for the BioMax®?

For electrical applications, primary technology competitors include standard, fossil fueled, engine generators of which there are many brands throughout the world and small PV and wind systems.

Relative to PV, a technology with a multi-billion dollar a year market, and growing at 35%, our current low volume, pre-commercial BioMax® 25 and 50 system are already more cost effective when compared on an equivalent energy basis.

For thermal applications, propane and natural gas are the major competing technologies. Biomass is significantly lower in fuel cost at levels from 0 to $4 per million btu vs natural gas at prices in excess of $10 per million btu in December 2005.

In the biomass systems arena, there are very few competitors. In the US, we are not aware of any in our size range.

In India, there are several companies who have considerable experience in small biopower systems, however the systems tend to be larger, not modular, not highly automated, and unable to pass US emissions requirements. We believe there a few companies in Europe that offer similar sized systems, however, they do not have a market presence in the US or in any of the developing country markets where we have business interests.

What should I do if I think I have a use for the BioMax®?

Click on this link, and answer the questions in the respective tables prior to contacting CPC.