Top-quality components. for your biogas plant

Transcription

1 Top-quality components for your biogas plant

2 Quality for your biogas plant The technology for producing biogas is extensive, and has developed continually in recent years. Whether a plant can be successfully integrated into an operation often stands or falls with the correct technology. Here, in addition to the combined package, the quality of the individual components of a biogas plant is often decisive. For this, the emphasis is on reliability and a long working life. With your Consentis component folder, you receive a comprehensive overview of the components of Consentis biogas plants. We have also listed the reasons why we recommend this technology. For more than 10 years we have been building turnkey biogas plants, and we are one of the leading international full service providers. All components are successfully proving themselves in continuous use in our own plants. They consist of industrially proven and top quality materials. In extensive quality tests, we select only those components in which we are fully confident. High energy yield, low digester loading, long dwell period, large fermenter volumes, and an appropriately large gas storage facility ensure efficient biogas production. As a full service provider, we provide entry-level models and large plants in the megawatt range. All types are characterised by low wear, and energy-saving operation. A team of specialists is by your side from the planning, through implementation, to successful operation of your biogas plant.

3 Contents Reinforced concrete containers 4-5 Holding containers and pits 6 Sight glass 7 Control cabinet 8 Workstation 9 Heating system 10 Heat distribution 11 Carrier air sheeting cover Agitator technology Pipework 16 Pump systems 17 Feed technology Power input 20 Biomethane feed 21 Gas processing 22 Sterilisation 23 Gas flare 24 Notes 25

4 Reinforced concrete containers Concrete containers Circular formwork constructed from segments All reinforced concrete containers are manufactured with a braced formwork system. This ensures accurate manufacturing and a high compression ratio of the concrete. The robust containers withstand extreme loads. Highly efficient thick-walled heat insulation is fitted beneath the floor plates and on the container walls. To avoid thermal bridges, the material is laid in two layers on the container walls. PERI GmbH 4

5 Heat insulation, trapezoid sheeting For gas-tight containers, the wall in the gas storage area is coated with a plastic sheet or with epoxy resin. The container crown is also coated with epoxy resin and protected with a SIKA membrane. In addition, the container is covered with weather-resistant aluminium trapezoid sheeting. Heat insulation 5

6 Holding containers and pits Holding container The liquid farmhouse manure is collected, stored, and homogenised in the holding pit or container. The substrates are then transferred to the fermenter for fermentation. Holding pit 6

7 Sight glass Sight glasses allow a rapid visual control of the fermenter content. In this way, the creating of floating layers, the functioning of the agitators, and the biological desulphurisation can be monitored. 7

8 Control cabinet The plant is very easy to operate by means of touchscreen, PC, smartphone (e.g. iphone) or remote data transfer. All drives can be controlled automatically or manually. Malfunction reports are recorded in the plant, and operational readiness is communicated by mobile phone. Intuitive operation is supported by computer via a PLC controller. All the important functions of the biogas plant are presented visually through the central control system. Important data such as level of fill, motor running, fermenter temperature can be read at any time. The data is archived, and can be analysed and monitored over elapsed time. A load management system spreads operational time points for pumps, agitators, and conveyor devices, in order to prevent load peaks. The biological process is unaffected. The supply level agreed with the energy supplier, which results in high cost penalties if it is exceeded, is maintained by the control system. This helps significantly in reducing the energy costs. 8

9 Workstation The plant can optionally be supplied equipped with a workstation in the control room. This is equipped with a PC and screen, and therefore offers a further option for monitoring and controlling the plant. 9

10 Heating system Heating system on the inside The heating system is dimensioned proportional to the requirements. The elements in the fermenter and post-fermenter, made from stainless steel, are attached to the inner wall of the container. Because of easy accessibility and the presence of frost protection, the distributors for the fermenter heating are in the pump room. The system consists of corrosion-resistant and diffusion-proof stainless steel pipes. All heating circuits are separate, and can be individually closed down. Distribution circuit in the pump house 10

11 Heat distribution Heat distribution ensures an optimum use of the heat energy from the CHP for fermenter heating and external users. The modularly built system has precisely fitted heat insulation. The components ensure maximum functionality even in tight spaces. 11

12 Carrier air sheeting cover above: Reinforcement for various wind zones Beam construction with net Gas storage and weather protection sheeting A beam construction is then placed on top of the opened concrete containers; this runs between the container wall and a middle support. The top of the concrete container is completely covered by a conical gas storage sheet. To protect against the effects of weather, the container is doubly covered by a second weather protection sheet, also conical in shape. These two sheets are attached to the container wall in a U-shaped sheet clamping track by means of a clamping hose. The double-layer roof thus constructed is characterised by simple installation and removal, as well as high resistance to diffusion. 12

13 Compressed air pressure maintenance unit Overpressure /underpressure protection Support air blower Roof fastening Gas fill level display To ventilate the intermediate space between the sheets, and to stabilise the roof, a support air blower is fitted externally to the container, with a downstream excess pressure valve. The support air blower is characterised by a modest power consumption. The biogas pressure remains constant regardless of the gas fill level. Overpressure / underpressure protection ensures that the support air sheet cover is not exposed to excessively high or low gas pressure. The regulation of the air supply by an air valve allows the pressure between the sheeting to be adapted to various operating conditions. The gas fill level display in the gas storage space is indicated on a gas level display. Sensors measure the gas fill level, which is processed in the plant control system, e.g. for CHP power control. The compressed air pressure measurement unit monitors the pressure in the clamping hose. 13

14 Agitator technology Insertion motor agitator Agitator adjustment The substrate mixture is the basis of life for the bacteria, and only agitation ensures their nutrition and the functionability of the biogas system as a whole. Insertion motor agitator The insertion motor agitator is used for the homogeneous mixing of the fermenter contents. It is characterised by low wear, and efficient circulation. The combination of large agitator blades and a low rotational speed results in a high transfer of energy, and therefore in efficient and energy-saving mixing of the substrate. The positioning of the agitator on the reinforced concrete container wall means that the height and direction of rotation of the agitators can be adjusted inside the biogas container, and thus adapted to individual requirements. 14

15 Flows and effects of the agitator during mixing and breaking up of the sinking and floating layers Motor Agitator with large blades Agitator with large blades If living raw materials are used, floating layers can result. This requires special agitation technology, i.e. the large blade agitator. The arrangement of the agitator rods and blades ensures both horizontal and vertical mixing. The use of four agitator blades with a diameter of 2.30 m results in an effective mixture of the floating and sinking layers. This improves gas development: more biogas is created in a shorter time. The gas potential of the substrate is exploited better. The large-bladed agitator is characterised by high effectiveness at a high solids content, a long working life, and a low energy consumption. 15

16 Pipework Biogas pipework Material valve with hand lever Valve shaft with substrate piping The plant is piped for gas and substrate in such a way that the containers can be individually disconnected for maintenance work. Top-quality knife-gate valves ensure permanently safe plant operation. All substrate pipework is systematically laid with frost protection, i.e. underground, within the containers, and in the pump room. The shaft lining consists of a wall ducting connected with a breakoff prevention device. The components are made of high quality stainless steel. Heat conduction Pneumatic gate valve 16

17 Pump systems Pump system Comminution devices The central pumping system is so designed that pumping between all fermenters, post-fermenters and substrate stores is possible at all times, independent of the direction. There are various pump types, depending on the characteristics of the plant and the relevant substrate. Rotary pumps are being increasingly used. These come under the category of displacement pumps. They are characterised by good pump performance and low energy consumption. In addition, there are comminution devices, which are a combination of wet comminutor and heavy material separator. These comminute specific fibres and coarse materials in liquid media. 17

18 Feed technology Vertical mixer, control unit (above left) Mixing screws with knife Vertical mixer The vertical mixer supports the creation of a homogeneous substrate mixture. This ensures a consistent nutrient supply to the fermenter. The mixer screws are fitted as standard with cutting knives to comminute the materials. By means of this feed technology, even heavy input materials such as grass silage, bale silage, and solid dung can be efficiently exploited. The lining consists of wear-resistant materials such as stainless steel and plastic. They guarantee a long working life. A central control unit displays the weight measured in the container, so that the various input materials can be optimally dosed. The vertical mixer is available in various sizes according to requirements. The delivery system offers advantageous start-up sizes for small plants. A screw conveyor system transfers the input material into the fermenter. This is a reliable and energy-saving method of solids delivery. All product-contact parts are made from V2A material, and all gas-contact parts are made from V4A material. 18

19 Compact floor conveyor Floor conveyor Screw system compact floor conveyor Screw system floor conveyor Floor conveyor system The floor conveyor system for large plants represents a well-priced conveyor system. The material is fed to the screw system by means of hydraulic rakes and conveyed to the fermenter. In addition to the floor conveyor system for large plants, the compact floor conveyor offers the perfect addition for the medium-sized biogas plant sector. The conveyor system is a robust solution for moving solid materials. It is characterised by energysaving and low wear technology. 19

20 Power input Co-generation unit in its building Co-generation unit in container Control cabinet The co-generation unit consists of a combustion engine operated by biogas. A matching generator creates electrical energy which is fed into the public mains network. The waste heat from the biogas engines is used for heating the substrate and, for example, for adjacent cattle sheds. The use of the heat outside the operation makes sense if the heat at the location can be used only to a small extent at best. The heat can then also be used at other locations by means of district heating connections or remote satellite CHPs. Gas engines are characterised by long working lives, high technical availability combined with a low maintenance effort, a high level of effectiveness, and low emission values. 20

21 Biomethane feed Gas processing offers the possibility of creating biogas derived from energy crops, wastes, and sewage sludge. The generated gas (biomethane or bio natural gas) is used with significantly greater efficiency on site or, after ducting to and feeding into the natural gas network, at another location. During gas generation, carbon dioxide and other products associated with gas generation, e.g. hydrogen sulphide, are removed. The methane content is increased from % to % (according to requirements). Biomethane plants are characterised by simplicity, operating stability, and flexibility. They can be set up in various sizes as standardised container plants or as individual onsite solutions. 21

22 Gas processing Active carbon filter / Gas scrubber / dryer Active carbon filter / Biogas cooling Gas cooling is a simple variant for the cooling of the biogas. On the other hand, gas scrubbing / drying is a combined process for cooling / drying and for the partial removal of undesired fermentation gases. Here, the water vapour contained in the gas is condensed out, and during the process silicates and suspended matter are removed from the biogas. A cold water mist at 0 C cools the biogas to less than 4 C. The scrubbed biogas ensures a longer working life for the spark plugs and the combustion engine. The active carbon filter is used for preparing and handling the gas, and is used downstream of the gas cooling or the gas scrubber / dryer. This reduces the wear on the engine and the engine oil, and the catalyser and exhaust heat exchanger are permanently protected. This reduces the maintenance costs. 22

23 Sterilisation Sterilisation containers Heat exchanger If wastes of animal origin (slaughterhouse wastes) are to be used in biogas plants, these must be sterilised. The substrate is heated in an additional process step. This means that the materials in the plant are bacterially harmless. Sterilised and unsterilised material is strictly separated; back-mixing of the two flows is impossible. 23

24 Gas flare The gas flare is used for the combustion of excess gas which occurs during overproduction or during a breakdown or stoppage of the co-generation unit. 24

25 Notes Notizen 25

26 Do you have questions? Just contact us! Consentis Anlagenbau GmbH, Am langen Graben 13, Wietmarschen, Germany Phone: +49 (0) / Fax: +49 (0) / info@consentis.de