BIOGAS PLANT CONSTRUCTION

Transcription

1 BIOGAS PLANT CONSTRUCTION for renewable raw material systems with high digester load Turnkey erection by the main contractor of biogas plants with a electric power of 300 kw onwards in the capacity Technology for dry fermentation of renewable raw materials with a certification by C.A.R.M.E.N. e.v. Erection of biogas fermenters, mainly individual components of various sizes Processing technology for renewable raw materials to ensure the highest fermentability and digester loading rates per unit volume of 5 to 7 kg ots/m 3 Optimal control of the biogas plants using high-tech solutions Software development for the operational management of biogas plants STIRL-Anlagentechnik GmbH Stellwerkswiese Krakow am See Telephone ( ) Fax ( ) info@stirlgmbh.de Website:

2 Assembly of fermenters Setting up a fermenter of a size suitable for the plant design: A cantilever roof provides a space of up to 450 m 3 for gas storage and protects all components installed inside the fermenter. The gas storage foil is not exposed to any kind of weather influences (wind, sunlight, rain, cold, etc.) The fermenter containers are made of VERINOX, which guarantees durability. The double-fold system ensures high stability and leak-tightness. The adjoining photograph shows folding machines for preparing a container. Assembly of the actuator of a paddle mixer for the prevention and removal of floating-layer formations inside. An optimised draining device guarantees reliable operation; a floating-layer formation outlet is used to drain impurities. Efficient heating of the outer wall and thick insulation of the container, optionally also of the roof, ensure lower heat requirement for a stable process and a maximum surplus heat for additional use elsewhere.

3 Plant design of SAT GmbH Krakow am See This schema shows the characteristic features of our biogas plant design: Our focus during the plant designing stage is on ensuring optimum conditions for the fermentation process. As a preferred variant, we have therefore opted for a system with direct insertion of liquid manure and extruded solid input materials. This technology supports all possible renewable raw materials that are solid, grainy, farinaceous, fibrous, chaff-shaped, liquid or similar. This extruder technology is the key element of a thermomechanical pulping system for renewable raw materials. Processing the input materials such as dung, maize silage, grass silage, grain-whole plant silage and similar increases the biogas yield substantially. Advantages of this process: - Surface enlargement of the biogenic product by fraying - High suction and water-binding capability of the processed materials - Breakdown of lignin resins, cellulose and hemicellulose - Prevention of floating-layer formations - Improvement of the C-N ratio - Reduction of the dwell time to 20 to 30 days with the highest level of utilisation of renewable raw materials This fulfils the important prerequisites for attaining digester loading rates per unit volume of more than 6.0 kg TS/m 3. Insertion of fiber-frayed biogenic materials also accelerates the biological decomposition of the carrier medium such as liquid manure. Generation of biogas from liquid manure and renewable raw materials thus ensures high efficiency. Apart from the guarantee of optimal fermentation conditions, the important features of our systems also include the V4A lining of the fermenter, functional and operational safety.

4 Special technical features of biogas plants All renewable raw materials are quickly transferred into the 20 to 40 m 3 collection dosing feeder. The liquid manure is first heated and then fed to the fermenter for wet fermentation. The crude gas containing 3000 to 5000 ppm H 2 S is desulphurised biologically and supplied to the cogeneration unit with 0 to 200 ppm using a gas cooler. The electronic and control devices is set-up in a separate room of the processing hall. The touch-screen of the PLC control unit allows an easy operation with a clear overview.

5 Turnkey biogas plants Steinhagen biogas plant, Meckl.-Vorp. (commissioning at the end of 2001) General view of the Steinhagen biogas plant Fermenter volume of 2 x 900 m 3 with 320 kw electric power of the cogeneration unit Medrow biogas plant, Meckl.-Vorp. (commissioning in autumn 2005) General view of the biogas plant 500 kw electric power using 2 x 800 m 3 fermenters Arrangement of the fermenter, the desulphuriser and the processing hall with grain storage Wotenick biogas plant, Meckl.-Vorp. (commissioning in summer 2006) General view of the biogas plant 500 kw electric power using 2 x 900 m 3 fermenters Velgast biogas plant, Meckl.-Vorp. (commissioning in winter 2006/07) Biogas plant with separate dry and wet fermentation 600 kw electric power using 1300 m m 3 fermenters

6 Werbig biogas plant, Brandenburg (commissioning in winter 2005/06) View of the fermenter and the desulphuriser 500 kw electric power using 1500 m 3 fermenter, CHP, processing hall and desulphuriser Pitschütz biogas plant, Sachsen (commissioning in winter 2006) 500 kw electric power generated from dry fermentation using 2 x 1100 m 3 fermenters Inside the processing hall collection dosing feeder and extruder technology Mieste biogas plant, Sachsen-Anhalt (commissioning in winter 2006/07) 350 kw electric power derived from wet fermentation using 1300 m 3 fermenter, extruder technology and external desulphurisation Eppendorf biogas plant, Sachsen (commissioning in winter 2006/07) General view of the biogas plant 350 kw electric power using 1300 m 3 fermenter

7 Obergruna biogas plant, Sachsen (commissioning in summer 2007) 350 kw electric power with 1300 m 3 fermenter Inside the processing hall pulping equipement Biogas plants being constructed in 2007/08 Löbnitz biogas plant, Meckl.-Vorp. (trial run from September 2007) 500 kw electric power derived from dry fermentation with 2 x 900 m 3 fermenters, extruder technology and external desulphurisation Krempin biogas plant, Meckl.-Vorp. 500 kw electric power derived from wet fermentation using 2 x 900 m 3 fermenters, extruder technology and external desulphurisation Wittstock biogas plant, Brandenburg 500 kw electric power derived from fermentation using 1500 m 3 fermenter, extruder technology and external desulphurisation Friedrichshof biogas plant, Meckl.-Vorp. 500 kw electric power derived from dry fermentation using 2 x 900 m 3 fermenters, extruder technology and external desulphurisation

8 What the plant operators say Should I invest 1-2 million euros on reconstructing the cow shed thatch to retain the liquid manure to set-up a biogas plant as it works only with liquid manure? Not required at all, as the design of SAT was exactly what we were looking for! We are obtaining 90% of electricity from the almost free of charge input material dung. W. Grübler, Chief Executive Officer, Agrarunternehmen Lommatzscher Pflege e.g. Using the extruder technology for the renewable raw materials will provide us with the opportunity to manufacture and sell fodder products by taking into account the weather conditions for agriculture and the market situation. N. Henke, Managing Director, Medrower Technik GmbH Using the whole plant silage of corn is a great way of stabilising the agricultural production in our light arable land. The biogas plant generates a high percentage of excess heat (> 60%) for our pig breeding facility; a valuable additional source of income. A. Vogel, Managing Director, Werbiger Energie GmbH With this technology, the biogas plant can be fed with enough input material to feed a cow that gives litre of milk; a prerequisite for high economic efficiency. G. von Oltersdorff-Kalettka, Managing Director, Wotenicker Technik GmbH