Embed Size (px)
Citation preview
Our references – incentives for your biogas project
Job reports
Dear Biogas Prospect,
It’s obvious: biogas is the only renewable energy source which is available for the gen eration of power and heat, and also as a fuel. That is why your biogas project should be in the right hands from the very start.
Through our Consentis reference dossier, we would like to present to you an up-to-date overview of the service provided by Consentis, and to introduce to you agri-cultural undertakings from home and abroad who have already entrusted us with their project, and who have since then successfully been producing biogas. In this way, we hope to give you an insight into our work, and to provide examples of how
Consentis biogas plants are implemented in practice. As you browse, we hope that we will give you ideas and suggestions for your biogas project.
Therefore: let yourself be inspired!
Should you require further information on one or more references, we will of course be delighted to help you at any time, either with detailed information on the plant, or with an on-site visit. We wish you an informative journey through the Consentis implementation of biogas production.
Consentis can do it! Listen to our customers.
Year built 2006
Output 1.67 MW (2 engines of 835 kW)
Input material Vegetable fats, maize
Solids in-feed 3 walking fl oors
Containers 3 digesters each 18 m Ø, 2 post-digesters each28 m Ø, digestion residue storage tank 35 m Ø
Heat concept ORC plant
Job report – Kloosterman, Nieuweroord (NL)
Heat concept with ORC plant
Johann Kloosterman’s biogas plant in Nieuweroord (Netherlands) generates elec-tricity and gas by means of a Consentis biogas plant built in 2006. Two engines create about 1.67 MW. The surplus heat is sufficient to feed a downstream ORC plant. The heat is converted into approximately 150 kWe electricity. Another part of the heat is used for the neighbouring residential buildings. In addition to maize as the typical input material, vegetable fats are also fed into the plant. Each of the three digesters has its own feeding system (walking floor).
The dwell time of the input materials in the three digesters is about 120 days. “What convinced me were the very good outout and the long working lives of the engines”, states Johann Kloosterman.
“I was sceptical at the start, because our system was the first plant built in the Netherlands by Consentis, but the service and the quality of the components has really won me over.”
Job report – Kloosterman, Nieuweroord (NL)
Control system Touchscreen operation
ORC plant Sight glassEngine in hall
Year built 2009
Output 500 kW
Input material Solid manure, forage rye, slurry
Solids in-feed 2 vertical mixers
Containers 2 digesters each 23 m Ø, post-digesters 30 m Ø, digestion residue storage tank 30 m Ø, slurry accepting tanks, collecting tank for seepage liquors and rainwater
Heat concept Clinic (satellite CHP)
Job report – CHP Overhoff , Baccum (D)
Biogas – a new income source for the business
The family operation at CHP Overhoff in Baccum, Lower Saxony, has been dealing in cattle for four generations. In 2009, a second income source was added to cat-tle dealing. As part of this, they decided on a biogas plant from Consentis with an output of 500 kW. It is operated using bovine manure and cattle slurry from their own cattle farming. “That is of course available in a cattle rearing area. We generate bio-energy and exploit our slurry,” says Hermann Overhoff.
And the heat concept has also been well thought out. By means of the energy generated, a satellite co-generation unit (CHP) is supplied with biogas. Because in this case biogas is transported instead of hot water, a significantly greater dis-tance can be travelled without loss. The heat released from power generation can be used economically. In this case, a clinic receives the resulting heat and uses it almost completely.
Job report – CHP Overhoff, Baccum (D)
Vertical mixer Filling and emptying locationFilling the vertical mixer Control system Gas flare
Engine in hall Pump system Satellite CHP
Year built 2008
Output 1.59 MW (1.07 MW and 526 kW)
Input material Maize, plant residues, vegetable fat
Solids in-feed Walking fl oor
Containers 2 digesters each 21 m Ø, post-digester 27.5 m Ø, digestion residue storage tank 27.5 m Ø
Heat concept Drying plant for digestion residues
Job report – Bouwhuis, Witteveen (NL)
Job report – Bouwhuis, Witteveen (NL)
Biogas production across the border
Gert Bouwhuis’s biogas plant in Witteveen (Netherlands), close to the German border, has been running since 2008. The unusual thing about his plant is that feeding system, two engines, intake pit, and office are all in one hall. For Farmer Bouwhuis the heat concept implemented by Consentis is valuable. The resulting heat is used for a drying unit. From one third of the digestion residue, this plant produces 800 tonnes of dried material each year; this is sold to market gardeners
for further use. Bouwhuis passes on the remaining two thirds of the digestion resi-due to farmers as high grade manure; they can apply this directly to agricultural land. In the Netherlands, the legal framework conditions on biogas production are different than in Germany. The Dutch renewable energy law, passed in 2008, defined a basic remuneration for the operators. In addition, they must negotiate their electricity price freely on the market.
Engine in hall CHP control
Maize silage Loading the walking floor
Drying plant Digestion residue (dried)
Year built 2009
Output 500 kW (2 engines of 250 kW)
Input material Maize, grass silage, solid manure, slurry
Solids in-feed Vertical mixer
Containers Digester 18 m Ø, post-digester, 26 m Ø,digestion residue storage tank 26 m Ø
Heat concept Adjacent stock sheds and residential houses (local heat network)
Job report – Meyer, Meppen-Bokeloh (D)
Engine in hall Agitator adjustmentCHP building Tank emptying area
Job report – Meyer, Meppen-Bokeloh (D)
Filling the vertical mixer Control systemControl system for vertical mixer Pump systemOverpressure/underpressure protection
Expansion planned
Hermann Meyer’s biogas plant in Meppen-Bokeloh, Lower Saxony, is a real family operation. With the energetic support of his daughter Katja, he oper-ates a plant built in 2009 and a cattle farm. He was so convinced by the newly built plant that he had it expanded to 500 kW in 2011. “After a brief start-up phase, the plant is running smoothly using maize, manure, and about five per-cent grass silage as input materials”, says Hermann Meyer. “Even with sub-strates such as grass silage which are difficult to ferment, the plants cope very
well. Above all the third and fourth grass cut, i.e. the late growth, makes a suit-able input material for the biogas plant.” Hermann Meyer uses the heat resulting from the process for heating the adjacent stock sheds and residential buildings via a local heat network. It was the nearness which went in favour of Consentis. “We decided on the turnkey supplier because we had already viewed several reference plants in the surrounding area, and the level of service won us over”, summarises Hermann Meyer.
Year built 2007
Output 3.58 MW (3 engines each 1.07 MW, 1 generator 370 kW)
Input material Organic wastes, slurry
Solids in-feed Vertical mixer
Containers 4 accepting tanks each 11 m Ø, 2 buff er tanks each 15.5 m Ø, 4 digesters each 25.5 m Ø, 2 post-digesters each 25.5 m Ø, 5 digestion residue storage tanks each 25.5 m Ø, hydrolysis container
Heat concept Wood drying, adjacent stock sheds (satellite CHP)
Job report – Bollmer Umwelt, Schwartenpohl (D)
3.58 MW installed electrical output
The Schwartenpohl nutrient recycling centre belongs to its operator and manag-ing director Georg Bollmer, and is located directly in the Consentis Anlagenbau catchment area. The biogas plant on an industrial scale was built in 2007 by the turnkey provider. Consentis, the all round service provider, also undertook plan-ning and applications. The plant has an installed electrical output of 3.58 MW. That corresponds to the requirements of around 6,000 households! Three engines with an output of 3.21 MW in total burn the biogas created, and drive the generators,
120,000 tonnes of biomass form the basis; the material comes from various sources e. g. from the foodstuffs industry. The plant has its own laboratory in which the biological processes are analysed. Supplied materials and fermentation sub-strates are regularly analysed there. The heat generated during the process is used for wood drying in containers, in the feed and turn dryer, and for adjacent stock sheds via the satellite CHP. Biomass heating plants, e. g. at nurseries, and other facilities take the dried wood chippings.
Job report – Bollmer Umwelt, Schwartenpohl (D)
Intake building Lab for biological process support
Hygienisation Heat distributorsFeed and turn drier CHP in its buildingGas scrubber dryer
Year built 2009
Output 220 kW
Input material Maize, slurry
Solids in-feed Vertical mixer
Containers Digester 18 m Ø, post-digester 21 m Ø,digestion residue storage tank 21 m Ø
Heat concept Hotel (via district heating connection), own cattle sheds
Job report – Sütthoff , Wietmarschen (D)
Simple start-up in biogas production
Located not far away from Consentis, the facility has a CHP module with a rating of 250 kW that uses the typical input materials, maize and slurry, to generate elec-tricity and heat in the biogas plant. The facility was extended in 2011 to include a satellite CHP unit for an additional 250 kW, as well as a digestion residue storage tank to increase the storage capacity. In 2011 the owner of the plant had his CHP system boosted to 220 kW. And in 2012 an additional digestion residue storage tank was constructed to increase the capacities of the plant.
The input material consists mainly of maize and slurry resulting from the farm’s own pig production.
By means of an intelligent heat concept which was implemented in collaboration with Consentis, the farmer supplies a hotel via a district heating connection, in addition to his own pig pens and household.
Job report – Sütthoff, Wietmarschen (D)
Motor in containerCHP container Heat concept for own stock sheds
Pump house with control room Maize silageVertical mixer Tank emptying area
Year built 2009
Output 400 kW (190 kW and 210 kW)
Input material Maize, slurry
Solids in-feed Combination of walking fl oor and vertical mixer
Containers Digester 18 m Ø, post-digester 21 m Ø,digestion residue storage tank 21 m Ø
Heat concept Neighbouring stock shed, own stock sheds and residential building (via district heating connection), drying plant for digestion residues
Job report – Klokkers, Laar (D)
“Benefit from the advantages of the renewable energy law”
For the plant operator Egbert Klokkers and his son Bernd, the easy start-up in bio-gas production and the support for smaller plants from the amendment to the renewable energy law were decisive for the construction of the biogas plant.
“A fair amount of slurry of course arises in calf fattening, but a 500 kW plant would have been too large for us. Since the 2009 amendment to the renewable energy law, it’s been worth our while to operate our small plant, close to the Dutch border.
We receive a guaranteed payment, and in addition we can produce heat and en-ergy from our slurry”, report the farmers, who became aware of Consentis through the company’s nearby reference plants. Suited to the framework requirements of the renewable energy law, and as an encouragement to smaller plants, Consentis Anlagenbau offers simple and efficient start-up models from a power output of 190 kW upwards. With the compact plant series, farmers have the possibility of setting up a second income source in a simple way.
Work station Delivery of input material
Job report – Klokkers, Laar (D)
CHP container Engine for the agitator with large blades Insertion motor agitatorAgitator with large blades
Year built 2011
Output 624 kW
Input material Swine slurry, maize, whole crop silage, grain
Solids in-feed Scraper chain buff ering and dosing system
Containers Digester 21 m Ø, post-digester 21 m Ø, 2 digestion residue storage tanks 30 m Ø
Heat concept 3 residential houses, fattening shed, grain drying area, feed hall
Job report – FS-Agrarenergie GmbH & Co. KG, Langwedel (D)
SchauglasEngine
Touchscreen operationFree-standing pump house
Conveyor system
Feeding systemFeeding system
Job report – FS-Agrarenergie GmbH & Co. KG, Langwedel (D)
Efficient energy production
Efficient energy production by means of a Consentis biogas plant is an important in-come source in addition to farming and pig fattening operations, and it makes use of solar power. The Consentis biogas plant has been designed for compatibility with the existing re-sources to ensure modern and – above all – sustainable crop rotation on the cultivat-ed areas. Wheat and barley for fodder are supplemented with maize. Yellow mustard is also planted as an intermediate crop. The biogas plant has an output of 624 kW el.
The input material, in addition to swine slurry, is maize, whole crop silage and grain. The heat utilisation concept is also interesting: The plant can heat three residential houses, two fattening sheds, the grain drying area and the feed hall.
The digester and the post-digester are designed with a diameter of 21 metres. An input dosing feeder is used for efficient feeding of solids to the plant. The slurry from the pig fattening operations is utilised in the biogas plant.
Year built 2011
Output 500 kW
Input material Chicken manure, cattle slurry, maize and swine slurry
Solids in-feed Walking fl oor / double-pressure conveyor screws
Containers 2 digesters 18 m Ø, post-digester 27 m Ø, 2 digestion residue storage tanks 32 m Ø
Heat concept 8 chicken sheds
Job report – Lüpken Energie GmbH & Co. KG, Dörpen (D)
Lüpken Energie GmbH & Co. KG – Cost-effective heating for poultry production
The two digesters with a diameter of 18 metres, have a feeding symstem with a walking floor and double pressure conveyor screws. The system als has a post-digest-er with a diameter of 24 metres and two digestion storage tanks with a diameter of 32 metres. The integrated heat concept is also interesting: The waste heat from the plant can heat a total of eight chicken sheds.
The company chose Consentis primarily due to the very efficient heat utilisation con-cept and the numerous functions and features of the plant.
The biogas plant is an additional source of income. Besides chicken manure, cattle slurry, maize and swine slurry are used.
SchauglasEngine
Gas processingAgitator adjustment
Sight glass
Job report – Lüpken Energie GmbH & Co. KG, Dörpen (D)
Year built 2009
Output 500 kW (250 kW engine and 250 kW Sat.-BHKW)
Input material Maize, slurry, sunfl owers
Solids in-feed Vertical mixer
Containers Digester 20 m Ø, post-digester 26 m Ø, digestion residue storage tank 32 m Ø
Heat concept Nursery (via district heating connection),own cattle sheds
Job report – Hüseman, Nordhorn (D)
“Adapt biogas plants to the individual location”
Located not far away from Consentis, the facility has a CHP module with a rating of 250 kW that uses the typical input materials, maize and slurry, to generate elec-tricity and heat in the biogas plant. The facility was extended in 2011 to include a satellite CHP unit for an additional 250 kW, as well as a digestion residue storage tank to increase the storage capacity. However, it is noteworthy that sunflowers are used as an input material.
This often creates a very energy-rich biogas. “But that works only with the right technology”, the farmer informs us. Consentis biogas plants can be individually adapted to the respective location and to the substrates used. In addition to feed-ing the public mains network, one part of the heat generated is used for his own pig pens, and a neighbouring nursery takes part via a district heating connection.
Worm system Sight glassesVertical mixer
Pump house with control room CHP container
Job report – Hüseman, Nordhorn (D)
Year built 2011
Output 250 kW
Input material Maize, slurry
Solids in-feed Compact walking fl oor
Containers Digester 22 m Ø, post-digester 27 m Ø, digestion residue storage tank 27 m Ø
Heat concept Owner’s pig production operations
Job report – Hof Plöns, Wielen (D)
Schauglas
Efficient drying of fermentation residue
The main incentive for construction of a 250 kW biogas plant at the Plöns farm in Wielen was to create an additional source of income. The input material used is maize and slurry. The digester (with a diameter of 22 metres) is efficiently supplied by means of a compact walking floor.
The system also has a post-digester with a diameter of 27 metres and one digester residue storage tank, also with a diameter of 27 metres.
The waste heat is used efficiently and with low loss in the owner’s pig production facilities. It is noteworthy that planning is already underway to expand the plant to 500 kW. A digestion residue drying unit will also be connected.
Pump house, inside
EngineCompact walking floor
Compact walking floor
Job report – Hof Plöns, Wielen (D)
Year built 2011
Output 500 kW
Input material Maize, chicken manure and slurry
Solids in-feed Compact walking fl oor
Containers 2 digesters 18 m Ø, post-digester 24 m Ø, digestion residue storage tank 32 m Ø
Heat concept Chicken sheds
Job report – RaWa Bioenergie GmbH & Co. KG, Dersum (D)
Schauglas
RaWa Bioenergie GmbH & Co. KG
The complete input supply and output utilisation were the focus of the biogas plant with an output of 500 kW completed in mid-2012 at RaWa Bioenergie GmbH & Co. KG. The input material is maize, chicken manure and slurry from the owner’s operations. The waste heat is used in the owner’s own chicken sheds.
The concept of the feeding system is also interesting: a compact floor conveyor is used here.
The plant consists of two digesters (18 metre diameter), the post-digester (24 metre diameter) and a digestion residue storage tank with a diameter of 32 metres. The integrated heat concept provides for high efficiency of the plant. This development created an additional source of income for the owner.
Feeding system
Heat distributorPump unit, RotercutTank emptying area
Engine
Job report – RaWa Bioenergie GmbH & Co. KG, Dersum (D)
Year built 2010
Output 190 kW
Input material Maize, grass, slurry
Solids in-feed Vertical mixer
Containers Digester 18 m Ø, post-digester/digestion residue storage tank 22 m Ø
Heat concept Residential houses and business premises (via a district heating connection), cereal and wood drying
Job report – Hof Struve Energie, Grauel (D)
Schauglas
“Even difficult substrates can be processed - no problem!”
In his business, young farmer Marc Struve relies on several income sources together. As well as a dairy farm with associated bull fattening and market fruit cultivation, he relies on biogas as an additional income source. In addition to the business premises, residential houses are heated via a district heating connection, and the business’s cereal and wood drying is supplied with heat.
Marc Struve decided in favour of Consentis, above all because of the Consentis full service concept. He very much appreciated dealing with only one contact partner throughout the planning and construction phase. “As well as that, there was no prob-lem in using a raw material substrate mix with difficult components, such as grass silage, in the Consentis digester”, is the verdict of this young farmer.
Job report – Hof Struve Energie, Grauel (D)
Worm system CHP container
Pump systemSight glasses
Engine in container
Maize silage
Year built 2010
Output 500 kW (350 kW and 150 kW)
Input material Maize, grass silage, whole crop silage, chicken manure, slurry
Solids in-feed Walking Floor
Containers Digester 25 m Ø, post-digester 25 m Ø,digestion residue storage tank 32 m Ø
Heat concept Pigsties and residential buildings (via district heating connection), chicken sheds (satellite CHP)
Job report – D+S Biogas, Meppen-Versen (D)
Schauglas
Sustainable and energy-efficient
For the shared biogas plant of the Düsing and Schepergerdes families from Meppen, the emphasis is on a high efficiency heat concept.
Thanks to biogas production, both businesses have achieved an optimum heat con-cept for the pigsties, in addition to a satellite CHP for the chicken sheds. And the plant also has a sustainable and secure substrate concept.
The area required belongs to the businesses, and is in the immediate vicinity of the farmyards. Overall, it was possible to significantly reduce the energy costs.
The two families chose Consentis on the basis of numerous recommendations from other farmers. Since it was commissioned, the plant has been running without prob-lems. The engines have a 98% loading, and the dwell time is about 120 days.
Job report – D+S Biogas, Meppen-Versen (D)
Desulphurisation
Tank emptying area
Engine in hallHall for walking floor and engine
Loading the floor conveyor
Year built 2010
Output 500 kW (2 engines of 250 kW)
Input material Maize, whole crop silage, slurry
Solids in-feed Combination of walking fl oor and vertical mixer
Containers Digester 22 m Ø, post-digester/digestion residue storage tank 31 m Ø
Heat concept Own stock sheds and drying plant for fermentation residues
Job report – Bioenergie Boysen, Steinbergkirche (D)
Schauglas
Bioenergie Boysen – Biogas is a key part of the concept
The biogas business line almost perfectly complements the agricultural business of the Boysen family from Schleswig-Holstein. As well as an agricultural enterprise, the family runs a pig fattening operation and an innovative contracting business.
In addition to sufficient land, slurry was therefore available, and there was optimum mechanisation for the biogas logistics.
The heat concept that has been achieved is also efficient and economical. The waste heat is used for heating the pigsties and a digestion residue drying plant. Maize, whole plant silage, and slurry are used as input substrates.
Job report – Bioenergie Boysen, Steinbergkirche (D)
Touchscreen operation
Loading the feeding system
Compressed air pressure maintenance unitCHP container
Feeding system
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
For your notes
Just contact us!Consentis Anlagenbau GmbH, Am langen Graben 13, D-49835 Wietmarschen, GermanyPhone: +49 (0) 59 25 / 99 86-0 • Fax: +49 (0) 59 25 / 99 86-11E-mail: [email protected] • www.consentis.de
Do you have questions?
CONSENTIS 10.2012
