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
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 3 / 24
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)
TECHNICAL SPECIFICATION
4 / 24
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
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 5 / 24
■ 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
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 6 / 24
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
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 7 / 24
■ 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
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 8 / 24
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
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 9 / 24
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
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 10 / 24
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.
TECHNICAL SPECIFICAT
1998-05 / 07.12.2010
■ 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
Wall or Ceiling Mounting Frame
■ 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
TECHNICAL SPECIFICATION
11 / 24
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
Wall or Ceiling Mounting Frame
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
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 12 / 24
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
TECHNICAL SPECIFICAT
1998-05 / 07.12.2010
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
TECHNICAL SPECIFICATION
13 / 24
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
TECHNICAL SPECIFICAT
1998-05 / 07.12.2010
■ 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
TECHNICAL SPECIFICATION
14 / 24
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
TECHNICAL SPECIFICAT
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
TECHNICAL SPECIFICATION
15 / 24
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-
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 16 / 24
■ 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
TECHNICAL SPECIFICAT
1998-05 / 07.12.2010
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
TECHNICAL SPECIFICATION
17 / 24
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
TECHNICAL SPECIFICAT
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
TECHNICAL SPECIFICATION
18 / 24
: 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-
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 19 / 24
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)
TECHNICAL SPECIFICAT
1998-05 / 07.12.2010
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
TECHNICAL SPECIFICATION
20 / 24
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
TECHNICAL SPECIFICAT
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.
TECHNICAL SPECIFICATION
21 / 24
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-
TECHNICAL SPECIFICAT
1998-05 / 07.12.2010
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
TECHNICAL SPECIFICATION
22 / 24
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-
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 23 / 24
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.-%
TECHNICAL SPECIFICATION
1998-05 / 07.12.2010 24 / 24
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.