Landfill Gas Coolers

About this Gig
Landfill gas is a notoriously difficult medium. It contains not only methane and CO2 but also volatile organic silicon compounds (VOSCs) known as siloxanes, which convert into abrasive silica during combustion, leading to severe engine damage.

To protect your power plant and maximize uptime, your gas cooling system must be more than just a heat exchanger - it must be a precision-engineered moisture and contaminant removal system.

RareTechSEA provides world-class design, rating, and optimization for LFG coolers, utilizing over 40 years of institutional knowledge to solve the complex interplay between thermal efficiency and corrosive resistance.

Case study
We designed, manufactured and commissioned one of the first Low Pressure LFG Coolers, placed on the low pressure side of the compressor with very constrained space constraints. Our allowable pressure drop was less than 50 Pa. The LFG Cooler increased motor up-time from hours to 3 months.

Full Scope of Supply

Thermal and Hydraulic Sizing

We perform rigorous calculations to ensure your finned-tube bundle can handle the high moisture content of LFG.

• Log-Mean Temperature Difference (∆Tlm)
  We optimize the cooling profile to ensure the gas reaches its required dew point for effective moisture separation.

• Pressure Drop Control
  Minimizing gas-side pressure drop is critical to reducing compressor parasitic load. We determine the optimal tube arrangement and fin pitch.

Specialized Material & Corrosion Strategy
LFG environments are highly corrosive due to H2S, CO2, and organic acids.

• Material Selection
  We evaluate the use of SS316L, Duplex Stainless Steel (2205/2507) or Titanium to resist pitting and stress-corrosion cracking.

• Fin Geometry
  We specify high-strength fin designs that provide mechanical stability and protection for the primary tube in aggressive atmospheres.

Moisture & Siloxane Abatement Integration

A gas cooler's primary job in an LFG circuit is to "knock out" water and contaminants before they reach the engine or carbon filters.

• Condensate Management
  We design the internal flow path and header pitch to facilitate the quick removal of condensate, preventing re-entrainment.

• Siloxane Strategy
  We provide the thermal data necessary to design secondary siloxane removal systems, ensuring the gas is clean enough to prevent abrasive silica buildup.

Advanced Process Simulation

Using industry-standard process simulation technologies, we can model the entire cooling circuit.

• Process Flow Diagrams (PFD)
  Integration of the cooler with your compressors, filters, and generating plant.

• Performance Prediction
  It is important to predict how changes in ambient temperature and gas composition will affect your heat transfer efficiency.

Required information from client

• Gas Composition
  Typical methane/CO2 ratio and known concentrations of H2S or Siloxanes (in mg/m3).

• Process Conditions
  Inlet gas temperature, flow rate (SCFM), and required outlet dew point.

• Cooling Medium
  Available cooling water temperature or ambient air data (for fin-fan configurations), or cold-water chillers.

• Site Constraints
  Spatial constraints. Surrounding pipework