TECHNICAL SPECIFICATION AGRAFERM BIOGAS PLANT TF 1500 · 2017-02-14 · Annular Foundation and Blinding Layer ... -05 / 07.12.2010 6 / 24 Leakage Control System LDPE sealing membrane

TECH NIC AL

SPECIF I CAT IO N

AGR AFE RM B I O G AS PLAN T

TF 1500

P R O J E C T : S Y M O N D S F A R M

O F F E R N U M B E R : 1 9 9 8 - 0 5

C O N T A C T P E R S O N : N O R M A N N I T Z E R

TECHNICAL SPECIFICATION

1998-05 / 07.12.2010 2 / 24

TABLE OF CONTENTS

1. Hopper Feeder ......................................................................................... 3

2. Fermentation Tank ................................................................................... 4

2.2 Sight gauges .................................................................................... 7

2.3 Overpressure protection .................................................................. 7

3. Fermentation Tank Stirring Mechanism .................................................... 8

4. Digestate Storage Tank ............................................................................ 9

4.2 Double-Membrane Gas Holder ...................................................... 10

5. CHP Unit with Gas Engine ...................................................................... 11

5.2 CHP Unit Building .......................................................................... 13

6. Intermediate Building .............................................................................. 14

7. Plant Technology .................................................................................... 15

7.1 Electrical, Measuring and Control Technology ............................... 15

7.2 Process Control Technology .......................................................... 17

7.3 Gate Valves ................................................................................... 18

7.4 Compressed Air Distribution .......................................................... 18

7.5 Pipelines ........................................................................................ 19

7.6 Structural Steel Work ..................................................................... 20

7.7 Condensate Shaft .......................................................................... 20

7.8 Pump Equipment ........................................................................... 21

7.9 Digestate Removal Station ............................................................. 21

8. Separation .............................................................................................. 22

8.2 Process Water Shaft ...................................................................... 22

9. Flare ....................................................................................................... 23

10. Gas Analysis .......................................................................................... 23


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1. Hopper Feeder

Extremely rugged and durable hopper feeder with adequate reserve power. Feeding takes place automatically at regular intervals administered evenly throughout the day.

Hopper feeder with screw conveyor and weighing device

Hopper

■ Hopper (steel, zinc-coated) in painted design featuring a special shape for optimum mixing of substrates and cofermentates, with inspection door

■ Max. bulk density: up to 0.55 t/m³ ■ Hopper volume: approx. 90 m³ ■ 3 mixing screws with knife-edges for homogenization and crushing of the sub-

strates ■ 1 output for connection of a screw conveyor

■ Mixing screws are driven by an electric motor ■ A galvanized frame and mechanical counterblades for optimum crushing of

the substrates are fitted as standard

■ Suited for all renewable raw materials ■ PLC control

■ Integrated weighing device

Screw Conveyor

■ Mounted directly to the mixing tank

■ Special gears for drive of the screws ■ Height: approx. 7 m

■ Minimum hoist capacity: 0,2 t/min ■ Substrates are fed into the fermenter with the galvanized feeding screw

TECHNICAL SPECIFICAT

1998-05 / 07.12.2010

2. Fermentation Tank

Manufacturer: Drössler

High-grade prefabricated fermentation tank made of qualityconcrete elements cast horizontally, with concrete ceiling and centre column

Agraferm Fermentation Tank

■ Wall construction in sandwich design

■ Composed of qualityments rounded at the inside)

■ Enhanced sulphate resistance up to 1,500 mg/l

■ In the water change zone area, the walls are protected by installaone PP plate (height approx. 1

■ The ceiling is insulated on the underside using 60 mm Styrodur

Tank of Precast Concrete Units

■ Height of external wall■ Inside diameter: ■ Gross volume:

■ Permissible media temperature■ Permissible gas overpressure

Wall Design

■ Material: ■ Class of resistance

■ Load-bearing leaf:■ Styrodur insulation

■ Facing leaf (facade)


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Fermentation Tank

Drössler

grade prefabricated fermentation tank made of quality-inspected reinforced horizontally, with concrete ceiling and centre column

ation Tank

construction in sandwich design (with integrated thermal insulation)

Composed of quality-inspected precast units (reinforced concrete elments rounded at the inside)

Enhanced sulphate resistance up to 1,500 mg/l

In the water change zone area, the walls are protected by installaone PP plate (height approx. 1 m) per wall element

The ceiling is insulated on the underside using 60 mm Styrodur

Concrete Units

Height of external wall: approx. 8.4 m approx. 18.6 m

approx. 2,300 m³

Permissible media temperature: 55 °C Permissible gas overpressure: up to 10 mbar

class C35/45 concrete, waterproofClass of resistance: XC4, XF3, XA2B

: tickness approx. 0.16 m Styrodur insulation: tickness approx. 0.08 m

Facing leaf (facade): tickness approx. 0.07 m

inspected reinforced horizontally, with concrete ceiling and centre column

(with integrated thermal insulation)

inspected precast units (reinforced concrete ele-

In the water change zone area, the walls are protected by installation of

The ceiling is insulated on the underside using 60 mm Styrodur

waterproof


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■ Finish facing leaf: form board marked, concrete grey

■ Embedding up to approx. 1.0 m ■ All necessary shaft linings, openings and sight gauges

■ Opening for additional shaft mixers, closed by a sealing plate ■ Inspection door / manhole (0.8 m x 0.8 m), incl. stainless steel frame and blind

cover

Base Slab

■ Material: class C25/30 concrete, waterproof

■ Class of resistance: XC4, XF3, XA1 ■ Slab thickness: 0.18 m ■ Double layer reinforcement of steel BST 500 M/500 S

■ Thermal insulation of base slab: rigid polystyrene foam under base slab

Ceiling

Concrete Ceiling consisting of single elements

■ Precast units system with centre column

■ Material: class C35/45 concrete, waterproof ■ Permissible pressure loading: 3.5 kN/m² ■ Thickness of ceiling: approx. 0.2 m

■ Openings for the agitators: approx. 1.6 m x 0.8 m ■ Shaft lining for gas pipe and overpressure / underpressure protection

■ Gas sampling fitting ■ On site, all joints are filled with foam on the underside and sealed gas-tight on

the upper side

Annular Foundation and Blinding Layer

■ Annular foundation: approx. 0.8 m x 0.2 m (W x H)

■ Concrete quality: C20/25 ■ Blinding layer: lean concrete, thickness approx. 5 cm


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Leakage Control System

■ LDPE sealing membrane (thickness: 0.8 mm), membrane carried up the tank to approx. 0.5 m

■ Ring drainage system with one inspection chamber ■ Any permission-related extra requirements to be charged in addition

Warranty for the tanks according to VOB (German construction contract procedures. The tank meets all requirements of the German standard DIN 11622 for liquid manure tanks. The tank tolerates placement in the groundwater for a maximum of 0.4 m. Where this mark is exceeded, pro-tection against uplift is required. This protection is not included in the of-fer.

Fermentation Tank Heating

Fermentation tank-Heat supply located in intermediate building/ individual

control of heating pipes

■ Insulated district heating pipeline for low-loss heat transport to the industry heating circuit distributors with integrated adjusting devices for flow control

■ Heating coils cast into the fermentation tank wall and bottom ■ For pipe feeding through the tank wall use is made of special bushings to effi-

ciently seal each individual tube of the heating circuits

■ Any thermal and mechanical stress is compensated for by the flexibility of the material

■ Temperature control is effected by means of the PLC controller

Biological Desulphurization

For desulphurization of the biogas, the side channel blower is used to constantly feed air into the fermentation tank, evenly in 3 different areas, by way of a PE pipe (DN 25).

Technical Data (Side Channel Blower)

■ Three-phase asynchronous motor: 400 V, 0.37 kW, 2900 rpm ■ Blow air volume (max.): 76 m³/h

■ Overpressure (max.): 95 mbar


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■ Sound level: 63 dB[A]

■ Weight: 13 kg

2.2 Sight gauges

Sight gauges

■ Two sight gauges about 0.5 m below the crest of the tank

■ Including lighting and wipers

2.3 Overpressure protection

Overpressure protection

■ Virtually maintenance free safety valve

■ Set pressure adjustable by weight loading ■ Insulated design


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3. Fermentation Tank Stirring Mechanism

Manufacturer: Maschinenbau Peters

Exceedingly stable paddle mixer on which Agraferm holds a patent and which has been specifically designed for renewable raw materials plants with high dry solids content

Agraferm Paddle Mixer with external agitator engine

■ The paddle mixer with integrated rolling-contact bearing can be re-moved for maintenance purposes or be replaced without interruption of operations and emptying of the tank

■ Gas-tight ceiling duct

■ Low maintenance and freely accessible agitator engine not affected by the temperature in the fermenter

Technical Data

■ Stirring mechanism height adapted to suit the fermentation tank ■ Paddle length: approx. 1.4 m; overall diameter: approx. 3 m ■ Material: high-grade steel; all metal parts in the gas section made of V4A

■ Speed control by means of frequency inverter ■ Rated power and speed of the reduction motor: 10 kW, 8 rpm

■ Drive: approx. 340 rpm ■ Mixer design meets ATEX IIG requirements

Wall or Ceiling Mounting Frame

■ Dimensions: approx. 0.9 m x 0.6 m ■ Material: 316L – V4A or equivalent


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4. Digestate Storage Tank

Manufacturer: Drössler GmbH

High-grade prefabricated tank made of quality-inspected reinforced concrete elements cast horizontally.

Digestate Storage Tank (shown with integrated gas holder)

Technical Data

■ Inside diameter: approx. 30.8 m ■ Wall thickness: approx. 0.18 m

■ Height of external wall: approx. 5.8 m ■ Volume: approx. 4.327 m³ ■ 4 openings for shaft mixers

■ All necessary shaft linings, openings and sight gauges as well as overpres-sure / underpressure protection (with roofed version)

■ Inspection door / manhole (0.8 m x 0.8 m), incl. stainless steel frame and blind cover

■ Class of resistance: XC4, XF3, XA2B

Base Slab

■ Material: class C25/30 concrete, impermeable to water

■ Class of resistance: XC4, XF3, XA1 ■ Double layer reinforcement ■ Slab thickness: approx. 0.18 m

Annular Foundation and Blinding Layer

■ Dimensions of annular foundation: approx. W x H = 0.8 m x 0.2 m; concrete class: C20/25

■ Blinding of lean concrete (approx. 0.05 m)

Measurement devices

■ Level meaurement device ■ Foam measurement device


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Leakage Control System

■ Installation of an LDPE sealing membrane (thickness: 0.8 mm), folding width of the membrane up to approx. 0.5 m from the tank bottom edge

■ Ring drainage system with one inspection chamber ■ Any permission-related extra requirements to be charged in addition

4.2 Double-Membrane Gas Holder

Double-membrane gas holder installed as a cover of the digestate storage tank. Inner membrane impermeable to gas and UV resistant outer membrane.

The double-membrane gas holder is placed on the crest of the tank. For this, a suspension system is mounted underneath the gas holder membrane, which is made up of straps fitted so as to radiate from the centre column of the tank to the outside directly underneath the crest of the tank. Use is made of the existing centre column, with the straps stretched horizontally directly from the column, or, where necessary this column is extended in height to the level required.

Double-Membrane Gas Holder

Inner Gas Membrane

■ Gas storage volume: approx. 2.850 m³

■ Working temperature: -30 °C to +70 °C ■ Working pressure: +/- 2.0 mbar (20 mm H2O)

■ Includes leak test after installation

Test report of Fachlaboratorium für Permeationsprüfung Pauly & Becker dated 26.06.2003 on methane diffusion through the roof membrane: Permeability to methane: 114 - 283 cm³/m² d bar (at 23 °C, according to DIN 53380 Part 2). Other diffusion parameters (gas and/or odour emis-sions) cannot be given as they vary with the composition of the ferment-ing mass.


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■ Reference is made to the fact that the medium stored is not allowed to contain any fractions of solvent

Outer Membrane

■ Working temperature:■ Temperature resistance (coating): ■ Maximum permissible snow load:

■ Material column: ■ UV, weather and liquid manure resistant roof membrane

■ Colour: window grey similar to RAL 7040 or moss green similar to RAL 6005

Filling Level Indication

■ Mechanical filling level measurement with electronic evaluation on process control system

■ Power rating:

■ Drive: ■ Mixer design meets ATEX IIG requirements


■ Dimensions: approx. 0.9 m x 0.6 m■ Material: 316L – V4A or equivalent

5. CHP Unit with Gas Engine

Manufacturer: GE Jenbacher

Jenbacher Gas Engine

JGS 420 GS-B.LC Model

■ 1413 kW electrical power

■ Jenbacher 20-cylinder V70 engine■ Four-cycle gas/Otto engine■ Oxidation catalyst


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Reference is made to the fact that the medium stored is not allowed to contain fractions of solvent-containing or solvent-like substances.

Working temperature: -30 °C to +70 °C Temperature resistance (coating): +80 °C (permanent load) Maximum permissible snow load: 50 kg/m²

galvanized, epoxy resin coated steelUV, weather and liquid manure resistant roof membrane

Colour: window grey similar to RAL 7040 or moss green similar to RAL 6005

Mechanical filling level measurement with electronic evaluation on process

15 kW

approx. 340 rpm Mixer design meets ATEX IIG requirements


Dimensions: approx. 0.9 m x 0.6 m V4A or equivalent

CHP Unit with Gas Engine

GE Jenbacher

Engine (Source: GE Jenbacher)

kW electrical power

cylinder V70 engine cycle gas/Otto engine

Oxidation catalyst

Reference is made to the fact that the medium stored is not allowed to contain

coated steel

Colour: window grey similar to RAL 7040 or moss green similar to RAL 6005

Mechanical filling level measurement with electronic evaluation on process


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JGS 420 GS-B.LC Technical Data at full load, standard conditions

■ Fuel: Biogas 50 % CH4 ■ Load factor: 100 %

■ Gasflow: approx. 670 Nm³/h acc. To DIN 3046 ■ Lubricating oil consumption: 0,44 kg/h ■ Electrical power output: 1413 kW el.

■ Electrical efficiency: 42,0 % ■ Thermal efficiency: 41,8 ± 8 %

■ Hot water circuit: ■ Flow temperature: 90 °C ■ Return temperature: 70 °C

The values indicated refer to the standard reference conditions. Any dev-iations from these standard reference conditions may result in shifts of the heat balance. The efficiencies indicated refer to manufacturer’s data and therefore cannot be guaranteed by Agraferm Technologies.

Technical Data

■ Mixture charging at low gas pressure

■ With two-stage mixture cooling ■ With high-performance spark plug

■ LEANOX lean mixture combustion control to minimize emissions

■ Compact design ■ Engine and generator are flange-mounted to each other and resiliently

mounted on the module frame ■ Installation of the set on insulating mats

Cylinder Head

Fitted for low-loss and consumption optimized gas change, developed specifically for GE JENBACHER lean mixture burning engines; water-cooled, made of special cast iron; separately replaceable, pressed-in valve seat inserts, valve guides and spark plug barrel; inlet and exhaust valves of high-quality material

Mixture Preparation

Gas mixer, turbocharger, mixture lines with compensators, water-flow mixture cooler, throttle valve and distributor lines to the cylinders

Ignition System

State-of-the-art non-contact high-performance distributorless electronic ignition system; firing point can be varied externally


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Lubricating Oil System

All movable parts are supplied with filtered pressure oil by the central lubricating oil gear pump. The lubricating oil circuit features pressure control valve and relief valve and replaceable-cartridge full flow filters. For cooling of the lubricating oil useof an oil heat exchanger.

Engine Accessories

Sensors on the Engine

■ Cooling water temperature sensor

■ Cooling water pressure sensor■ Oil temperature sensor■ Oil pressure sensor

■ Mixture temperature sensor■ Charge pressure sensor

■ MIN and MAX oil level sw■ Exhaust gas thermocouple per cylinder

■ Knock sensors ■ Gas mixer position detector

Gas Conditioning

■ Gas drying by cooling down

5.2 CHP Unit Building

Jenbacher CHP Unit Building

ISO Container

■ Dimensions: 12.2 m x 2.4 m■ Rock wool sheets for sound insulation■ Compact concrete building as a complete ready

■ Floor plan: Module room, chimney and sound absorber room, switchgear room

■ Special concrete formula to meet oil


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movable parts are supplied with filtered pressure oil by the central lubricating oil gear pump. The lubricating oil circuit features pressure control valve and relief valve

cartridge full flow filters. For cooling of the lubricating oil use

Cooling water temperature sensor

Cooling water pressure sensor Oil temperature sensor Oil pressure sensor

Mixture temperature sensor Charge pressure sensor

MIN and MAX oil level switch Exhaust gas thermocouple per cylinder

Gas mixer position detector

Gas drying by cooling down

CHP Unit Building

CHP Unit Building (here depicted as concrete building)

12.2 m x 2.4 m x 2.7 m (LxWxH) Rock wool sheets for sound insulation Compact concrete building as a complete ready-to-fit unit

Floor plan: Module room, chimney and sound absorber room, switchgear

Special concrete formula to meet oil-tightness requirements

movable parts are supplied with filtered pressure oil by the central lubricating oil gear pump. The lubricating oil circuit features pressure control valve and relief valve

cartridge full flow filters. For cooling of the lubricating oil use is made

(here depicted as concrete building)

Floor plan: Module room, chimney and sound absorber room, switchgear


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■ Internal walls and ceiling with two coats of white wash

■ External door/internal door: doubleDIN EN 20140, anti

■ Access opening in gable enables module replacement without dismantling of roof element

■ Table cooler on building roof

6. Intermediate Building

Agraferm Intermediate Building incl. pump equipment

Parameters of Cubicle (Concrete Building) Type Drössler

■ Dimensions:

■ Wall thickness: ■ Roof thickness:

■ Flat roof ■ Roof drainage ■ Ventilation openings in the wall

■ Earth can be backfilled against the building up to 0.5 m without reinforcement■ Weatherproof plaster


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walls and ceiling with two coats of white wash-fast paint

External door/internal door: double-walled steel door, sound attenuating to DIN EN 20140, anti-panic lock

Access opening in gable enables module replacement without dismantling of

cooler on building roof

Intermediate Building

Agraferm Intermediate Building incl. pump equipment

Parameters of Cubicle (Concrete Building) Type Drössler

approx. 4.5 x 7 x 3 m (WxLxH)

approx. 0.16 m approx. 0.18 m

Ventilation openings in the wall

Earth can be backfilled against the building up to 0.5 m without reinforcementWeatherproof plaster

fast paint

walled steel door, sound attenuating to

Access opening in gable enables module replacement without dismantling of

x 7 x 3 m (WxLxH)

Earth can be backfilled against the building up to 0.5 m without reinforcement


1998-05 / 07.12.2010

7. Plant Technology

Agraferm Control Technology

7.1 Electrical, Measuring and Control

Control and Automation

■ Centralized control of the plant by a programmable logic controller (PLC)■ Custom programming for the process in a biogas plant

■ Operation of all machines at the switching station or local control station■ Battery-backed direct current power supply unit to ensure operation of the

CPU/PLC controller during a power failure (UPS)■ Monitoring, storage and logging of the operating data, measuring values, fil

ing levels and temperatures

Safety Concept

■ System failures are remediedtions or reboot the system

■ Power failures at the computer are buffered for a certain period of time by an uninterruptible power supply system

Measurement Methods and Technology

■ Detection of quantity in

■ Measurement of fermentation tank filling level by pressure sensor■ Foam measurement in fermentation tank by foam sensor■ Temperature measurement in fermentation tank

■ Measurement of gas holder filling level■ Signal evaluation by PLC

Cabling and Installation Technology

■ Cable bundles inside the buildings laid either on cable racks (galvanized dsign) or in cable ducts

■ Individual lines with heavying saddles


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Plant Technology

Agraferm Control Technology

Electrical, Measuring and Control Technology

Centralized control of the plant by a programmable logic controller (PLC)Custom programming for the process in a biogas plant

Operation of all machines at the switching station or local control stationdirect current power supply unit to ensure operation of the

CPU/PLC controller during a power failure (UPS) Monitoring, storage and logging of the operating data, measuring values, filing levels and temperatures

System failures are remedied by monitoring functions which restart applictions or reboot the system Power failures at the computer are buffered for a certain period of time by an uninterruptible power supply system

Measurement Methods and Technology

Detection of quantity in Hopper Feeder by weighing cells

Measurement of fermentation tank filling level by pressure sensorFoam measurement in fermentation tank by foam sensor Temperature measurement in fermentation tank

Measurement of gas holder filling level Signal evaluation by PLC

ling and Installation Technology

Cable bundles inside the buildings laid either on cable racks (galvanized dsign) or in cable ducts

Individual lines with heavy-gauge plastic conduit surface mounted with spa

Centralized control of the plant by a programmable logic controller (PLC)

Operation of all machines at the switching station or local control station direct current power supply unit to ensure operation of the

Monitoring, storage and logging of the operating data, measuring values, fill-

by monitoring functions which restart applica-

Power failures at the computer are buffered for a certain period of time by an

Measurement of fermentation tank filling level by pressure sensor

Cable bundles inside the buildings laid either on cable racks (galvanized de-

gauge plastic conduit surface mounted with spac-


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■ For outdoor installation, cables always laid in UV resistant conduits

■ Lines buried in the ground in NYY/NYCWY design; lines inside buildings NYM versions (PVC sheath)

■ Measuring and signal lines in shielded design ■ Buried measuring and data lines in A-2YF design (approved for burying in the

ground)

Low Voltage Main Distribution

■ Switching station in rugged steel cabinets with interior lighting (linear lumi-naire)

■ Forced ventilation to avoid heat accumulations ■ Electrical heating, 50 W (thermostat controlled), to prevent formation of con-

densation water in bay 1 (control cabinet, PLC with industry PC) ■ For protection of the machinery and pipelines, the busbars feature fuse load

disconnectors/diazed fuses (bar-mounting fuse elements) ■ Display of the most important current values on the PC in the process control

system ■ On the front side of the switchgear cabinets are located:

Main switch to enable the system; emergency stop pushbutton; measuring and indicating instruments (operational states: On, Off, Malfunction); flush-type switches/pushbuttons on front wall for operation of the machines

Design of Outgoing Circuits

■ Protection by circuit breakers, motor protection switches or automatic circuit breakers

■ Frequency inverter, soft start, star-delta connection or instant start, depending on requirements

Earthing and Equipotential Bonding

■ Steel strip in galvanized design ■ All connecting elements, terminals in the ground in galvanized design

■ Earth conductors connected with central equipotential bonding strip ■ Evidence of the efficiency of equipotential bonding and earthing by a test

record

Surge Protection, Lightning Protection

■ Lightning protection system to TÜV requirements, internal and external earth-ing and full equipotential bonding

■ Coarse and medium protection by surge diverter in the switchgear behind the supply

■ Fine protector for protection of the control circuits and the measuring and sig-nal lines against overvoltage


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7.2 Process Control Technology

Based on many years of experience and developed exclusively for Agraferm biogas plants. Particularly clear layomalfunctions.

Agraferm Process Interface

Process Control System Functions

■ Monitoring of the plant■ Documentation of the process

■ Evaluation of the operating condition also over extended periods of t■ Evidence and documentation of the operating condition in the form of daily,

monthly and annual reports■ In the event of malfunctions, the process control system outputs a message to

the plant owner and indicates cause and location of the malfunction

Visualization

■ Representation of process and of overall plant in dynamic overview display

■ Colour display of operating condition of the machines■ Indication of all analog values at the measuring point■ Status bar with important messages

■ All archived data and the optimize operation

Archiving

■ Storing of the process data in standard Windows format at regular intervals

■ Free access for customized evaluations■ Manual input menu enables evaluation and logging of data whic

lected automatically (e.g., type of substrate)

Logging

■ Logging of operating condition and mass balances in Excel spreadsheets, regular creation of records and evaluations

■ The plant owner has unrestricted access to the logs and can rework them make further use of them at his discretion


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Process Control Technology

Based on many years of experience and developed exclusively for Agraferm biogas plants. Particularly clear layout and ease of operation. Automatic alerting in case of

Agraferm Process Interface

Process Control System Functions

Monitoring of the plant Documentation of the process

Evaluation of the operating condition also over extended periods of tEvidence and documentation of the operating condition in the form of daily, monthly and annual reports In the event of malfunctions, the process control system outputs a message to the plant owner and indicates cause and location of the malfunction

Representation of process and of overall plant in dynamic overview display

Colour display of operating condition of the machines Indication of all analog values at the measuring point Status bar with important messages

All archived data and the current data can be evaluated in graphical form to optimize operation

Storing of the process data in standard Windows format at regular intervals

Free access for customized evaluations Manual input menu enables evaluation and logging of data whiclected automatically (e.g., type of substrate)

Logging of operating condition and mass balances in Excel spreadsheets, regular creation of records and evaluations The plant owner has unrestricted access to the logs and can rework them make further use of them at his discretion

Based on many years of experience and developed exclusively for Agraferm biogas ut and ease of operation. Automatic alerting in case of

Evaluation of the operating condition also over extended periods of time Evidence and documentation of the operating condition in the form of daily,

In the event of malfunctions, the process control system outputs a message to the plant owner and indicates cause and location of the malfunction

Representation of process and of overall plant in dynamic overview display

current data can be evaluated in graphical form to

Storing of the process data in standard Windows format at regular intervals

Manual input menu enables evaluation and logging of data which are not col-

Logging of operating condition and mass balances in Excel spreadsheets,

The plant owner has unrestricted access to the logs and can rework them or


1998-05 / 07.12.2010

7.3 Gate Valves

Gate valve: manual and pneumatic control

The DN 150 discharging pipe installed at the fermentation tank features a gate valve in handwheel design. For safety reasons, operation of the gate valve by hand must be possible at all times.

Pneumatic Gate Valves

■ Gate valve plate of stainless steel 1.4301■ Pneumatic drive

■ Control via PLC, 24 V control voltage■ Pipe end gate valve design

7.4 Compressed Air

Kaeser Piston Compressor

■ Air-cooled compressor block with ring oil lubrication■ Suction air filter with silencer■ Aluminium cylinder heads and additional cooling pipes for optimum heat di

sipation ■ Lightweight low-noise reed valves

■ Compressor and motor directly coupled■ Integrated axial fan for cooling of compressor and motor■ Four-pole motor, 1,500 rpm, three


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: manual and pneumatic control

The DN 150 discharging pipe installed at the fermentation tank features a gate valve in design. For safety reasons, operation of the gate valve by hand must be

Gate valve plate of stainless steel 1.4301

Control via PLC, 24 V control voltage Pipe end gate valve design

Distribution

Kaeser Piston Compressor

cooled compressor block with ring oil lubrication Suction air filter with silencer Aluminium cylinder heads and additional cooling pipes for optimum heat di

noise reed valves

and motor directly coupled Integrated axial fan for cooling of compressor and motor

pole motor, 1,500 rpm, three-phase current 400 V/50 Hz

The DN 150 discharging pipe installed at the fermentation tank features a gate valve in design. For safety reasons, operation of the gate valve by hand must be

Aluminium cylinder heads and additional cooling pipes for optimum heat dis-


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7.5 Pipelines

Substrate Pipes

Substrate pipes of stainless steel (above ground)

■ Buried pipes of PE-HD ■ Pipes laid above ground of stainless steel (transition above soil)

■ Suction / delivery pipes nominal size: DN 150 ■ Pressure rating: PN 10 ■ Pipe bushings of stainless steel, sealed by an annular space seal

Gas Pipelines

Gas Pipelines (oberirdisch stainless steel/ buried pipes PE-HD)

■ Buried pipes of PE-HD with socket welding, yellow

■ Pipes laid above ground of stainless steel with screwed flange ■ Nominal size: DN 150 ■ Pressure rating: PN 4

■ Wall bushings of stainless steel ■ Laying of the gas pipes with approx. 1 % gradient to the condensate separator

■ Butterfly valves (as specified by DVGW)


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7.6 Structural Steel Work

Staircases, platform

■ Staircases (width ca. 0,8m) and railing to fermenter and intermediate building with standard grid irons as Cover panel. The steps of the staisteps as well, hot-exit to the intermediate building.

■ Digestate storage tank with Maintenance platform and ladder to the stirring mechanism

■ All frameworks are certified (TÜV).

7.7 Condensate Shaft

Condensate Shaft with cover

■ Round container DN 1500

■ Concrete: class C35/45 to DIN 1045■ Wall thickness 15 cm, consisting of lower part with bottom and cored holes■ A cup inside the container with liquid receiver prevents the escape of

■ The condensate filling level is monitored continuously and disposal is effected by an integrated pump

■ Hailo HS 3 stainless steel shaft cover■ Surface water tight with weather resistant seal■ Shaft cover - safe against flooding:

Cover: highly sturdy desigoutside mounted hinges, gas pressurized spring


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Structural Steel Work

Staircases, platform

Staircases (width ca. 0,8m) and railing to fermenter and intermediate building with standard grid irons as Cover panel. The steps of the stair being gridiron

-dip galvanized and designed as a bolted structure with an exit to the intermediate building. Digestate storage tank with Maintenance platform and ladder to the stirring

All frameworks are certified (TÜV).

Condensate Shaft

Condensate Shaft with cover

Round container DN 1500

Concrete: class C35/45 to DIN 1045-4 Wall thickness 15 cm, consisting of lower part with bottom and cored holesA cup inside the container with liquid receiver prevents the escape of

The condensate filling level is monitored continuously and disposal is effected by an integrated pump

Hailo HS 3 stainless steel shaft cover Surface water tight with weather resistant seal

safe against flooding: Cover: highly sturdy design with strutting for at least 1 m water column, with outside mounted hinges, gas pressurized spring

Staircases (width ca. 0,8m) and railing to fermenter and intermediate building r being gridiron

dip galvanized and designed as a bolted structure with an

Digestate storage tank with Maintenance platform and ladder to the stirring

Wall thickness 15 cm, consisting of lower part with bottom and cored holes A cup inside the container with liquid receiver prevents the escape of gas

The condensate filling level is monitored continuously and disposal is effected

n with strutting for at least 1 m water column, with


1998-05 / 07.12.2010

■ Self-engaging locking device and closing device, operating key and vapour escape

■ Frame: cylinder with circumferential seal

7.8 Pump Equipment

Pump equipment (Intermediate Building), Eccentric Screw Pump

Wangen GmbH)

Central Pump

■ Eccentric screw pump

■ Temperature monitoring using PT100 temperature sensor■ Nominal pressure

■ 3.0 kW spur geared motor■ Flow rate: standard up to 15 m³/h

7.9 Digestate Removal Station

Digestate Removal Station

■ For the system use is made of class C35/45 concrete to DIN 1045■ The shaft covered by a gridiron serves for collection of any overflowed su

strate and, by shifting of the gate valves, can be pumped dry using moval vehicle.

■ A predetermined breaking point and an additional gate valve prevent damage to, or draining of, the substrate container in case the shaft is torn off by ouside influences.

■ The shaft structure doubles as a bump protection device.


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engaging locking device and closing device, operating key and vapour

Frame: cylinder with circumferential seal

Pump Equipment

Intermediate Building), Eccentric Screw Pump

Eccentric screw pump

Temperature monitoring using PT100 temperature sensor Nominal pressure:up to 4 bar

3.0 kW spur geared motor Flow rate: standard up to 15 m³/h

Removal Station

Digestate Removal Station

For the system use is made of class C35/45 concrete to DIN 1045The shaft covered by a gridiron serves for collection of any overflowed sustrate and, by shifting of the gate valves, can be pumped dry using

A predetermined breaking point and an additional gate valve prevent damage to, or draining of, the substrate container in case the shaft is torn off by ou

The shaft structure doubles as a bump protection device.

engaging locking device and closing device, operating key and vapour

Intermediate Building), Eccentric Screw Pump (Source:

For the system use is made of class C35/45 concrete to DIN 1045-4. The shaft covered by a gridiron serves for collection of any overflowed sub-strate and, by shifting of the gate valves, can be pumped dry using the re-

A predetermined breaking point and an additional gate valve prevent damage to, or draining of, the substrate container in case the shaft is torn off by out-


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8. Separation

FAN Separator

Technical Data

■ Press screw separator model■ Screen length:

■ Power rating: ■ Includes switch cabinet. motor protection switch. belt conveyor or screw co

veyor

8.2 Process Water Shaft

Process Water Shaft

■ Round container DN 2500■ Capacity:

■ Material: ■ Wall thickness 0.15 m, consisting of lower part with bottom and cored holes

■ The filling level is permanently monitored and forwarded to thpre pipe

■ The filling level is monitored continuously and disposal is effected by an intgrated pump

■ Hailo HS 3 stainless steel shaft cover


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Press screw separator model: PSS3.2-1040 1.04 m

7.5 kW Includes switch cabinet. motor protection switch. belt conveyor or screw co

Process Water Shaft

Process Water Shaft

ntainer DN 2500 approx. 8 m³

class C35/45 concrete (DIN 104515 m, consisting of lower part with bottom and cored holes

The filling level is permanently monitored and forwarded to the main pipe by a

filling level is monitored continuously and disposal is effected by an int

Hailo HS 3 stainless steel shaft cover

Includes switch cabinet. motor protection switch. belt conveyor or screw con-

DIN 1045-4) 15 m, consisting of lower part with bottom and cored holes

e main pipe by a

filling level is monitored continuously and disposal is effected by an inte-


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9. Flare

Flare

Technical Data

■ Flow rate: up to 800 m³/h ■ Primary pressure: >25 mbar

■ Ambient temperature: -10°C to +60°C ■ Sound level: approx. 65 dBA

■ Engineering grades: made of stainless steel ■ Gas containing parts: made of material 1.4571 ■ Combustion chamber: made of material 1.4828

■ Fully assembled incl. wiring

Equipped with:

■ Radial compressor, flare-controlled ■ Shut-off device for manual operation ■ Deflagration arrester, BAM-certificate

■ On-site switchboard; protection type: IP 56 ■ Automatic ignition device with ignition electrode (ignition transformer 7.5 kV)

■ Automatic main gas-valve (free from non-ferrous metals); slow resolve/quick shutoff

■ Condensate trap with drain plug

10. Gas Analysis

High grade equipped gas analysis system for process control.

Sensors

■ Methane (CH4); measuring range: 0-100 Vol.-% ■ Hydrogen sulfide (H2S); measuring range: 0-200 ppm

■ Carbon dioxide (CO2); measuring range: 0-100 Vol.-% ■ Oxygen (O2); measuring range: 0-25 Vol.-%


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Technical Data

■ Stainless steel housing (HxWxD = 650x450x250 mm) for wall mounting ■ Graphic display of the course of measured values

■ Up to 50 measurements a day ■ Incl. calibration station

The present specification (state as on 25.01.2010) and all the information contained in it reflect the current state of the art. It is subject to change for commercial or technical reasons!

All illustrations serve for exemplification and are provided without liability.

Documents

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