Internal Digester Heating Systems
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1 Internal Digester Heating Systems BioCycle 12 th Annual Conference on Renewable Energy and Organics Recycling, October 29-30, 2012 Slide 1 / 37 BioCycle Renewable Energy 2012
2 Internal Digester Heating Systems Overview! Introduction of the BRUGG Organization! Different types of digester heating systems! Internal digester heating systems! Considerations for the selection of internal digester heating systems! Sizing of continuous corrugated stainless steel pipe heating systems! Installation of continuous corrugated stainless steel pipe heating systems! Maintenance of corrugated stainless steel pipe heating systems Slide 2 / 37 BioCycle Renewable Energy 2012
3 The Brugg group Headquartered in Brugg, Switzerland Headquarter in the town of Brugg, 30 km west of Zurich. Slide 3 / 37 BioCycle Renewable Energy 2012
4 Divisions Cable systems Wire rope technology Piping systems Process control systems Slide 4 / 37 BioCycle Renewable Energy 2012
5 Brugg Pipesystems BRUGG Rohrsysteme GmbH, Wunstorf German Pipe GmbH, Nordhausen Brugg Rohrsystem AG, Kleindöttingen Slide 5 / 37 BioCycle Renewable Energy 2012
6 Internal Digester Heating Systems Overview! Introduction of the BRUGG Organization! Different types of digester heating systems! Internal digester heating systems! Considerations for the selection of internal digester heating systems! Sizing of continuous corrugated stainless steel pipe heating systems! Installation of continuous corrugated stainless steel pipe heating systems! Maintenance of corrugated stainless steel pipe heating systems Slide 6 / 37 BioCycle Renewable Energy 2012
7 Digester Heating Systems 1. External Heating Systems e.g. Heat Exchanger to pre-heat the input material to process temperature Genset Substrate Heat Exchanger Slide 7 / 37 BioCycle Renewable Energy 2012
8 Digester Heating Systems 1. External Heating Systems e.g. Heat Exchanger to pre-heat the input material to process temperature 2. Internal Heating Systems e.g. Heating pipes installed right at the digester wall Genset Slide 8 / 37 BioCycle Renewable Energy 2012
9 Internal Heating Systems Smooth bore pipe e.g. 2 / DN50 (stainless) steel Slide 9 / 37 BioCycle Renewable Energy 2012
10 Internal Heating Systems Smooth bore pipe e.g. 2 / DN50 (stainless) steel Plastic pipe e.g. 1 / DN25 polyethylene Slide 10 / 37 BioCycle Renewable Energy 2012
11 Internal Heating Systems smooth bore pipe e.g. 2 / DN50 (stainless) steel Plastic pipe e.g. 1 / DN25 polyethylene Corrugated pipe 2 / DN50 Stainless steel 316 L Slide 11 / 37 BioCycle Renewable Energy 2012
12 Internal Heating Systems Considerations for the selection of internal pipe heating systems Heat Transfer? Durability? Installation? Slide 12 / 37 BioCycle Renewable Energy 2012
13 Heat Transfer Carbon steel PE-pipe Corrugated stainless Carbon steel has reasonable heat transfer properties Polyethylene has poor heat transfer properties Helically corrugated stainless steel has excellent heat transfer properties but wall thickness of approx. 2mm. and wall thickness above carbon steel. and through corrugation has 40% more heat transfer area than smooth bore pipe. Medium heat transfer efficiency low heat transfer efficiency = large amount of pipe to be installed Excellent heat transfer properties = minimum amount of pipe to be installed Slide 13 / 37 BioCycle Renewable Energy 2012
14 Efficiency of Heat Transfer Heat transfer from hot water to substrate subject to: heat conductivity of pipe material Stainless Steel = 30 W / m*k Carbon Steel = 80 W / m*k Polyethylene = 0,5 W / m*k Slide 14 / 37 BioCycle Renewable Energy 2012
15 Efficiency of Heat Transfer Heat transfer from hot water to substrate subject to: heat conductivity of pipe material Internal heat transfer rate! from hot water to the pipe surface Slide 15 / 37 BioCycle Renewable Energy 2012
16 Heat Transfer in Corrugated Pipe Turbulent flow condition Inside the pipe Eddy current in corrugation improves heat transfer rate Optimum heat transfer from heating medium through pipe wall Slide 16 / 37 BioCycle Renewable Energy 2012
17 Efficiency of Heat Transfer Heat transfer from hot water to substrate subject to: heat conductivity of pipe material Internal heat transfer! from hot water to the pipe surface external heat transfer! from pipe wall to substrate Slide 17 / 37 BioCycle Renewable Energy 2012
18 Heat Transfer in Corrugated Pipe Agitated flow outside Corrugation increases heat transfer to the substrate Optimum heat transfer from heating medium to substrate Slide 18 / 37 BioCycle Renewable Energy 2012
19 Efficiency of Heat Transfer Heat transfer from hot water to substrate subject to: heat conductivity of pipe material Internal heat transfer! from hot water to the pipe surface external heat transfer! from pipe wall to substrate Actual heat exchange surface per length of pipe Slide 19 / 37 BioCycle Renewable Energy 2012
20 Efficiency of Heat Transfer Straight pipe 2 more surface + 40% less pipe Corrugated pipe 2 Slide 20 / 37 BioCycle Renewable Energy 2012
21 Efficiency of Heat Transfer ca. 200% Slide 21 / 37 BioCycle Renewable Energy 2012
22 Efficiency of Heat Transfer EXAMPLE: Biogas plant Schnega (Lower Saxony) Replacement of plastic pipes with corrugated stainless steel pipes heating loops length Q circuits [ m ] [ kw ] PE pipes Corrugated ss pipes Slide 22 / 37 BioCycle Renewable Energy 2012
23 Digester Heating Considerations for the selection of internal pipe heating systems Heat Transfer! Durability? Installation? Slide 23 / 37 BioCycle Renewable Energy 2012
24 Carbon steel Installation PE-pipe Corrugated Stainless Pipe sections need to be bent prior to installation Plastic pipes are endless and flexible Flexible stainless steel pipe and welded or threaded frequently creating multiple potential leak points! but large quantities required due to limited heat transfer. no joints inside digester and smallest quantity of pipe to be installed! High labor costs and potential leaks over time! Easy installation, but lots of pipe and supports to be installed! Easy and fast installation, long life! Slide 24 / 37 BioCycle Renewable Energy 2012
25 Installation 1. Installation of pipe supports 2. Unrolling the pipe 3. Attaching the pipe 4. Installation of end fittings 5. Completed digester pipe installation endless pipe quick installation reduction of installation time reduction of installation costs Installation of the digester heating system in just a few hours Slide 25 / 37 BioCycle Renewable Energy 2012
26 Digester Heating Considerations for the selection of internal pipe heating systems Heat Transfer! Durability? Installation! Slide 26 / 37 BioCycle Renewable Energy 2012
27 Durability Carbon steel PE-pipe Corrugated Stainless Welded or threaded joints over time can be subject Plastic (PEX) pipe over time is subject Flexible stainless steel pipe to Microbiological Induced Corrosion (MIC)! to diffusion and reduction of plasticizer. no joints or welds inside digester Reduced lifetime and higher maintenance / replacement costs! Reduced lifetime and higher maintenance / replacement costs! Long lifetime and no maintenance! Slide 27 / 37 BioCycle Renewable Energy 2012
28 Efficiency of Heat Transfer EXAMPLE: Biogas plant Schnega (Lower Saxony) Replacement of plastic pipes with corrugated stainless steel pipes heating loops length Q circuits [ m ] [ kw ] PE pipes Corrugated ss pipes Slide 28 / 37 BioCycle Renewable Energy 2012
29 BIOFLEX Digester Heating System BIOFLEX 2 corrugated pipe Endless " no joints Wall thickness 0.02 Stainless steel 316L Slide 29 / 37 BioCycle Renewable Energy 2012
30 The World of BIOFLEX " Germany > 7200 Biogasplants > 800 equipped with BIOFLEX " Italy 500 Biogas plants in total > 45 supplied with BIOFLEX " Poland " Great Britain " Netherlands " Latvia " Switzerland " Austria " Spain " France " Hungary " Denmark " Finland In Europe more than 900 Biogas plants equipped with corrugated stainless steel pipe BIOFLEX Slide 30 / 37 BioCycle Renewable Energy 2012
31 The World of BIOFLEX " Germany > 7200 Biogasplants > 800 equipped with BIOFLEX " Italy 500 Biogas plants in total > 45 supplied with BIOFLEX " Poland " Great Britain " Netherlands " Latvia " Switzerland " Austria " Spain " France " Hungary " Denmark " Finland Slide 31 / 37 BioCycle Renewable Energy 2012
32 The World of BIOFLEX 6 BRUGG Pipesystems, LLC Rome, GA In the United States 25 digesters equipped with corrugated stainless steel pipe BIOFLEX " Oregon Junction City Aumsville Dayton " Pennsylvania Salunga " North Carolina Magnolia 2x " South Carolina Moncks Corner " Ohio Akron " New York Lawnhurst " Wisconsin Fond du Lac Alma Center Slide 32 / 37 BioCycle Renewable Energy 2012
33 US References Project: Loch Mead Farms in Junction City, OR Revolution Energy Solutions! 2 Digesters, Volume xxxx ft.!, ø xx ft.! sequentional batch! psychrophillic (approximately 80 F) Digester heating system (per digester)! 2 heating circuits! 4 loops in total! pipe run 595 ft. Slide 33 / 37 BioCycle Renewable Energy 2012
34 US References Project: KB Compost Services, Akron, OH Workman Industrial! 2 Digesters, Volume xxxx ft.!, ø xx ft.! mesophillic (approximately 100 F) digester heating system (per digester)! 4 heating circuits! 4 loops in total! pipe run 860 ft. Slide 34 / 37 BioCycle Renewable Energy 2012
35 Conclusions For a efficient biogas production it is necessary to maintain proper process temperatures Different types of heat exchangers (external / internal) Different types of pipe for internal heat exchangers Best choice: Stainless steel corrugated pipe! BIOFLEX by BRUGG Pipesystems LLC Slide 35 / 37 BioCycle Renewable Energy 2012
36 Thank you for your attention Slide 36 / 37 BioCycle Renewable Energy 2012
37 Thank you for your attention Meik Schubert Product Manager, Dipl.-Ing., M.Sc. BRUGG Pipesystems GmbH Telephone Mobile meik.schubert@brugg.de USA Contact Urs Maire, M.Sc. BRUGG Pipesystems, LLC Telephone : Mobile : maire.urs@brugg.com Slide 37 / 37 BioCycle Renewable Energy 2012
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