Landfill gas is one of the most valuable, yet most demanding, fuels used in power generation today. Turning it into a dependable source of electricity requires equipment that can cope with its unique characteristics day in, day out, without unplanned downtime. That’s exactly the role of a gas pumping set — a purpose-built fuel skid designed to move landfill gas from collection point to generator safely, efficiently, and reliably.
Why Landfill Gas Needs a Purpose-Built Fuel Skid
The single most important requirement for any fuel skid is long-term reliability. When a landfill gas pumping system goes down unexpectedly, the consequences are immediate — lost power generation revenue and potential compliance issues at the site. This makes robust, application-specific engineering non-negotiable.
Landfill gas is not the same as natural gas or biogas produced in anaerobic digesters. It has its own distinct profile of challenges:
- High moisture content, leading to significant condensate drop-out within the gas stream
- A wide range of corrosive trace gases, including halogens, ammonia, and mercaptans
Because of these factors, equipment designed for natural gas or generic biogas applications simply isn’t suitable. A landfill gas fuel skid must be engineered from the ground up to handle these conditions.
Gas-pumping units manufactured and supplied by Organics have a well-established record of providing landfill gas to generators with up-times in excess of 99%.
How Gas Pumping Sets Work
At its core, a gas pumping set draws landfill gas from the collection network, conditions it, and delivers it at the correct pressure and quality to the generator or flare. The system is built around several integrated subsystems working together:
Gas Blowers
The heart of the skid is the gas blower itself. Boosters with back-swept blades are preferred, since they resist surging at low flow rates — an important consideration given the variable gas production typical of landfill sites over their operational lifetime.
Moisture and Condensate Management
Given the high moisture levels inherent to landfill gas, automatic moisture removal is essential. Each unit includes a condensate knockout pot complete with a demisting filter and level switching, ensuring that collected condensate is automatically managed rather than allowed to accumulate and cause problems downstream.
Temperature and Dew-Point Control
Compressing a gas inevitably raises its temperature. Where a maximum temperature is specified as part of the gas quality requirements, air-blast cooling and/or refrigeration systems can be added to the skid. These systems also help manage relative humidity and dew point — a critical factor in preventing condensation-related issues in downstream equipment.
Safety Systems
Safety is built into every layer of the design:
- All equipment complies with applicable international standards for electrical equipment in potentially hazardous areas
- Flame arresters are fitted on both the inlet and outlet of the gas blower to prevent flash-back
- Powered slam-shut valves provide automatic emergency isolation where appropriate
- Specific instrumentation, such as a temperature transducer to detect flashback at the flame arrester and a motor-mounted thermistor to detect overheating, adds further protection
Technical Specifications
| Parameter | Specification |
|---|---|
| Flow rates available | 50 to 20,000 m³/hour |
| Standard materials | Hot-dip galvanised carbon steel |
| Optional materials | Stainless steel and high-grade alloys |
| Suction pressure head | Rarely exceeds 150 mbar (deep-vacuum systems can be accommodated) |
| Delivery pressure head (centrifugal blowers) | 300 to 600 mbar g (twin-stage) |
| Delivery pressure head (higher pressure options) | Up to 200 bar g via screw compressors, rotary vane compressors, or multi-stage reciprocating compressors |
Standard Scope of Supply
Every gas pumping set is supplied as a skid-mounted package, allowing full pre-delivery testing at the factory before the unit is shipped for final on-site assembly. This approach ensures equipment arrives ready for rapid installation and commissioning. Clients can also arrange factory inspection and witness testing prior to delivery.
The standard scope of supply typically includes:
- Gas blower, sized and configured for the specific application
- Condensate knockout pot with demisting filter and level switching
- Flame arresters on the inlet and outlet of the gas blower
- Facilities for pressure control to the point of use
- Standard instrumentation for pressure, temperature, and flow measurement
- Specific instrumentation for flashback detection and overheating protection
Optional Extras
Depending on site requirements, several additional features can be specified:
- Low or ultra-low emissions flare for continuous relief flaring
- Elevated candlestick flare for site trials and temporary flaring
- Gas analysers for compositional monitoring
- Internet connection facilities for remote, on-line monitoring
- Speed controllers for fine-tuning pressure and flow while also saving power
Individual gas boosters are typically skid-mounted, and may also be housed within individual GRP enclosures for additional weather and corrosion protection.
Site-Specific Design and Integration
No two landfill sites are identical, and gas pumping sets are designed accordingly. Site-specific engineering accounts for variations in gas flow, composition, and pressure requirements, while integrated control systems can be linked directly into a site’s main control centre for centralized monitoring and management. Design and specification services are available to help operators select the right configuration from the outset.
Key Takeaways
- Landfill gas is a uniquely challenging fuel due to high moisture content and corrosive trace gases like halogens, ammonia, and mercaptans — it requires equipment engineered specifically for the application.
- Gas pumping sets combine blowers, condensate management, temperature control, and comprehensive safety systems into a single skid-mounted, factory-tested package.
- Flow rates range from 50 to 20,000 m³/hour, with delivery pressures from 300–600 mbar g using centrifugal blowers, up to 200 bar g with compressors.
- Optional features such as flaring systems, gas analysers, remote monitoring, and speed controllers allow the system to be tailored to specific site needs.
- Well-engineered fuel skids can achieve operational up-times in excess of 99%, directly protecting power generation revenue.
Get in Touch
If you’re planning a landfill gas power generation project and need a fuel skid built for long-term reliability, our technical sales team can help you specify the right gas pumping set for your site. Contact us today to discuss flow rates, materials, and control options tailored to your application.