ThyssenKrupp Nirosta Discusses Stainless Steel Tanks for Anaerobic Digestion Plants

I for one think of stainess steel as a premium cost material and have not considered it likely to be a cost-effective material for a large commerical biogas tank, and yet in the article that follows it is clear that this material is being used for biogas plants, and reportedly, very successfully. We have included much of the article below, but please also visit the original website.

In Szeged, around an hour south of Budapest, Weltec Biopower is currently building an ultramodern biogas plant with stainless steel from ThyssenKrupp Nirosta. The 1-megawatt facility, comprising two combined heat and power plants with an output of 600 kW/h each, will go into operation at the end of 2011. The organic waste substrate will be supplied by local farmers, who in return will use the digestate left over from the anaerobic digestion /biogasproduction process as fertilizer on their fields. The generated heat will be used to heat offices in Szeged.

At the heart of the plant are two stainless steel digesters. In addition, an external stainless steel gas storage tank with a capacity of 650 cubic meters will be installed on the site. The aim is to take advantage of electricity prices, which are twice as high during the daytime. The biogas will therefore be collected in the digester tank and the external gas tank at night and the two CHP modules will run under full load in the day time.

The two 3,000 cubic meter digesters are sealed with a double membrane roof, which means that each digester also has an additional gas buffer capacity of 1,016 cubic meters. Animal waste and energy crops are used as a substrate, with special bacteria being used for the fermenting process. During biogas production, waste products such as sulfur and ammonia are also formed. "These substances are very corrosive, placing high demands on the material for the digesters. That's why we use stainless steel exclusively for our plants," says Hajo Schierhold, head of sales and marketing at Weltec Biopower, whose sole supplier of stainless steel is ThyssenKrupp Nirosta.

In the past ten years ThyssenKrupp Nirosta has supplied around 1,500 tons of material for various projects carried out by the Vechta-based plant builder. Depending on the loading, different stainless steel grades are used, e.g. for the tank walls in contact with the liquid or gas. "The majority of our deliveries have been our standard sheet steel Nirosta 4301 specially optimized for these applications," says Martin Stöckl from the ThyssenKrupp Nirosta sales team.

"What's particularly important for us is the cold-worked condition, 2H. This means thinner steel can be used to build the digesters without any loss of stability. It also means a significant cost saving". Another advantage is the extremely smooth surface. "The dense surface of Nirosta 4301 2H gives aggressive substances no opportunity to attack the material," says Weltec Biopower sales chief Schierhold. "Bacteria have no chance to take hold, so corrosion is nipped in the bud, which is an important factor for longevity and efficiency."

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Biogas Plant Approved Near Diss Norfolk But Local Objections Remain

Campaigners have vowed to launch a judicial review after controversial plans to build a biogas renewable energy plant near their homes were approved. In this article from Cogeneration & On-Site Power Production Magazine, it is not clear why the local continue to object. Is this Nymby-ism at play or do they have a specific objection? I suspect that Cogeneration & On-Site Power Production Magazine must think not, or the article would contain that information?

(The video is not linked with the article, but we hope you find it interesting.)

Stephen Gordon, chairman of Kenninghall Parish Council, announced that objectors would not give up their 18-month fight following the decision by Breckland Council's planning committee yesterday.

About 30 residents from the south Norfolk village, near Diss, attended the meeting with placards and protest banners.

Greenshoots Energy Ltd had applied to build an anaerobic digestion unit on land off Garboldisham Road, which would be fuelled with locally grown maize, poultry litter and cattle slurry. The electricity created would be transferred to the National Grid. The plant would be linked to a combined heat and power (CHP) plant just over half a mile away at Crown Milling, off Heath Road, which would use the waste heat generated by the energy plant.

Both applications had been recommended for approval despite opposition from the parish council, North Lopham Parish Council and about 500 residents who had signed a petition.

James Alston, who runs Greenshoots Energy with fellow farmer Robert Gooderham, said creating anaerobic digestors helped farmers maintain the viability of their industry.

Copyright 2011 Archant Regional Limited
All Rights Reserved

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Northern Ireland Opens New biogas CHP plant - Cogeneration & On-Site Power Production Magazine

A farm near Ardstraw in Northern Ireland is converting organic matter into biogas to provide sustainable heat and power on-site, as well as for local homes and businesses.

The 700-acre Greenhill farm biogas plant plant is only the second such plant in Northern Ireland. It works by ‘cooking’ animal waste from 600 cows at 40°C to produce methane gas.

The gas is then piped into two engines that drive generators to produce electricity. Hot water is also produced and is used to dry the plant’s residual, as well to pasteurise milk.

According to Alfagy, which supplied the biogas CHP, it has an energy efficiency of 86%, and represents a significant step toward in achieving an energy sustainable Northern Ireland.

The plant produces 430 kWh of power, which is sufficient to supply around 430 homes.

After the process of extracting methane from the manure and vegetation, farmers use the residual waste as a fertiliser to grow animal feed.

Alfagy says the project faced challenges in attracting funding from banks during the financial crisis.

“It is astonishing that more financial support isn’t directed at biogas power plants as they create eight times more value than other renewable technologies such as wind turbines,” says Peter Kindt, Alfagy’s chairman.

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Dong targets biomass-fired CHP in the UK - Cogeneration & On-Site Power Production Magazine

Denmark's largest power producer says it is looking at the UK as a potential location for power plants that convert household waste to energy.

The UK government has said it wants to see an expansion in waste-to-energy and anaerobic digestion plants and has recently increased incentives for on-farm biogas technologies.

But so far the industry has been taking a wait-and-see approach until the government reveals further details on the future structure of renewable energy subsidies before it commits to new waste-to-energy plants.

Dong has a history in the biomass market and currently produces heat and electricity at three waste-fired CHP plants in Jutland, Denmark.

Dong has also established a consortium to investigate the potential of bioenergy technologies and which is also tasked with converting an existing biomass-fired CHP plant to allow it to handle waste products from a bioethanol plant.

(Video is not reated to the article.)

The company is also looking at the possibility of constructing a waste treatment plant that will use enzymes to separate waste fractions for use in biogas production.

For more biomas news click here

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EBRD Lends 5.0 Mln Euro to Croatia's Agrokor for Biogas Power Plant - Cogeneration & On-Site Power Production Magazine

ZAGREB (Croatia), September 15 (SeeNews) - The European Bank for Reconstruction and Development (EBRD) said on Thursday it is providing a 5.0 million euro ($6.9 million) loan to Croatian concern Agrokor to support the construction of a combined heat and power generation plant that will use biogas as primary fuel.

The proceeds of the EBRD loan will be used to purchase and install the biogas power plant, and sterilisation and water purification equipment, the EBRD said in a press release.

The project is expected to be completed by September 2012 and will be in full compliance with EU environmental regulations.

Located in Gradec, 40 kilometres outside the capital Zagreb, the plant will be fuelled by organic waste, by-products of Agrokor's food production process. It will have a generation capacity of 1.0 megawatts (MW) of electricity, which will be supplied to Croatia's power grid, and also a 1.0 MW of heat capacity.

The construction of the biogas facility in Gradec is the first step in Agrokor's strategic plans to develop similar projects, with a total generation capacity of up to 30 MW, the statement said.

The EBRD has a long-standing cooperation with the privately-held Agrokor, having previously supported a variety of the company's investments in Croatia and neighbouring countries. The biogas facility in Gradec is financed under the bank's Agribusiness Sustainable Investment Facility.

Since the beginning of its operations in Croatia, the bank has committed over 2.5 billion euro to the country's economy. The EBRD funds mobilised additional investment of 4.0 billion euro in various sectors of the Croatian economy.

($ = 0.7246 euro)

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German Weltec Biopower completes fifth biogas project in Czech Republic - Cogeneration & On-Site Power Production Magazine

(SeeNews Renewables) - Sep 16, 2011 - German green energy solutions developer Weltec Biopower has finished its fifth biogas power plant in the Czech Republic, after four months of construction and approval by the responsible authorities.

The foundation was laid in March, followed by the installation of the 2,500 cu m stainless steel fermenter, the cogenerator and the 35 cu m vertical batcher. The biogas processing equipment came in May and the test operations started in June, when the plant also received regulatory approval.

The plant's 366 kW gas engine feeds electricity into the grid. The facility runs on agricultural substrates and manure from the nearby farms. The investors received financial support from the EU fund for both environmental issues and rural and agricultural development.

The Czech government sets top priority on green energy production and by 2015 biomass should provide the bigger share of it. This moves players from the country and abroad to invest in the sector. [ http://anaerobic-digestion.com ]

Copyright 2011 SeeNews.
All Rights Reserved.
www.seenews.com | www.world.seenews.com; e-mail: editor@seenews.com.

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Hungarian biogas CHP plant opens - Cogeneration & On-Site Power Production Magazine

Hungary’s largest biogas power plant was officially opened on 13 September in the city of Szarvas, where it will provide 4.2 MW of electricity and an equal amount of heat, supporting onsite operations and feeding the local grid.

(It is not clear whether this video is for the same power plant as in the article.)

German company r.e Bioenergie built the combined cooling, heat and power (CCHP) plant, which features three Jenbacher J416 engines supplied by GE.

The plant is being run in close co-operation with the poultry processing plant operator Gallicoop Pulykafeldolgozó, which provides much of the raw biomass that is converted into biogas to power the Jenbacher engines.

The anaerobic digestion facility is about 4 km east of the poultry processing plant. To optimize the efficiency of the thermal energy, a special pipeline delivers the biogas from the digester facility to the Jenbacher engines at the processing plant.

The CCHP system’s thermal power is then used to supply on-site heating and cooling. Any excess electricity is fed into the local grid.

For more biomass news click here

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Camartec appeals for massive biogas production - IPPmedia

The Centre for Agriculture Mechanisation and Rural Technology (Camartec) has appealed for more government budget allocation to boost biogas production that could help many power users cope with the current energy crisis.

(The video above is about a related biogas project.)

Biogas which is pollution-free and clean gas is seen as an option for rural and peri-urban low and medium income earners as it can easily produce energy for their daily domestic needs, such as cooking, heating and lighting.

Camartec is implementing biogas project across the country, and so far a total of 12,000 biogas plants are to be constructed under the first phase of the project set to cost euro 16 million to completion 2013.

“But budget constraints remained a challenge to spread the biogas technology across Tanzania especially for rural-based communities,” Camartec director general Evarist Ng'wandu said.

Speaking to media practitioners here recently, engineer Ng’wandu stressed the need to allocate more financial resources in the Ministry of Industry, Trade and Marketing.

“This will help to boost the biogas anaerobic-digestion sector in Tanzania which is affordable and simple in rural and peri-urban households,” he said.

The official noted that despite its economic and environmental significance, the 29-year-old centre is constrained with a number of challenges, one being shortage of funds.

Camartec is responsible for carrying-out different researches as well as promoting improved household stoves, community stoves, biogas and solar energy facilities, he noted.

“But all these couldn’t be reached if there are no funds to accomplish all these responsibilities,” he said.

“Our centre has increased services to 11 regions and managed to train technicians to install over 500 biogas plants in those areas,” Ng’wandu said

He added that agriculture alone will not succeed without industrial development; hence the need to allocate more funds in the sector remained crucial.

He however commended government efforts in developing biogas technology, whereby in five-years between 2007 and 2013, the centre plans to install about 12,000 biogas plants across the country.

Started in 1982, the centre was meant to produce and disseminate agricultural implements such as harrow planters, nutshells, oil press machines, wheelbarrows, pulling and oxen carts, water harvesting tanks and brick making tools.

Among other things, Camartec also pioneered to develop biogas technology, the innovation intended to be among the responses to skyrocketing oil prices in the world market in 1970s.

A plant used to produce biogas, also known as a biodigester, is an anaerobic digester that treats farm wastes or energy crops. This has been mostly the case in the developed countries where in recent years the technology has assumed new importance because of advanced methods of waste treatment.

In most developing countries, however, domestic biogas plants convert livestock manure into gas. The technology has been feasible for smallholders with livestock producing at least 50 kgs of manure per day.

Recently, Camartec launched a large-scale production of biodigesters that could help many families cope with the crisis.

The project, as a component of the African Biogas Partnership Programme (ABPP), known as Tanzania Domestic Biogas Programme (TDBP), is funded by The Netherlands, through its directorate of international cooperation.

Programme coordinator Lehada Cyprian Shilla, once expressed optimism over its potential to alleviate current energy woes as it would provide cleaner and safer energy solutions at a household level.

When it was officially inaugurated by Vice President Mohamed Gharib Bilal, a total of 1,439 units had been constructed under the programme in various regions  giving Tanzania a lead ahead of other nations where the initiative is being undertaken in Africa.

“Besides, providing an alternative source of energy to households currently faced with rising kerosene prices and worsening electricity crisis, the programme is expected to stimulate the private sector’s participation in the development of biogas technology and sale of a gas "that is affordable and simple in rural and peri-urban households,” he said.

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Anaerobic Digestion - Gas Production

A typical gas system comprises the digester cover, pressure and vacuum relief devices, water trap, flame trap, pressure regulator, gas meter, check valve, pressure gauges, waste gas burner and a gas holder. Mixing of digesters by means of gas re-circulation requires a compressor.




The digester is covered to contain odours, maintain temperature, keeps air out and to collect the gas. Fixed covers are more usual than floating covers. During normal operation, there is a space for gas collection between the cover and the liquid surface of the digester contents. The cover of a digester has certain unique features that the operating staff must be aware of, for example, how the variation in pressure and the level inside the digester may affect the cover. The biggest danger associated with the operation of fixed cover digesters occurs when the pressure relief device mounted on top of the digester fails or the sludge overflow line blocks and the liquid level in the digester continues to rise. In such a situation, the excess gas pressure inside the digester can exceed the maximum design pressure and damage the cover or its mountings. Fixed covers can also be damaged by excess negative pressure (vacuum) or if the rate of waste sludge withdrawal exceeds the feed rate or the vacuum relief device fails.

The function of the pressure relief device is to allow pressure that exceeds a safe level to escape from the digester. The manufacturer's specifications should provide the following information to enable the operating staff to control the gas system safely. (a) The system's normal operating pressure (mm water gauge). (b) The pressure at which the pressure relief device should operate. (c) The rated gas flow capacity of the pipes.

A gas system generally comprises three pressure relief devices; one mounted on the cover of the digester, one on the gas holder and one situated at the end of the gas line before the gas burner. This device releases gas to the waste gas burner before the design gas pressure of the digester cover is reached.

The vacuum relief device functions in the opposite manner to the pressure relief device and allows air to enter the digester in the event of the waste sludge being withdrawn too rapidly. Air should not, under normal conditions, be allowed to enter the digester because a mixture of air and methane is potentially highly explosive.

Gas leaving the digester is almost saturated with water vapour. As the gas cools, the water vapour condenses causing problems. The problem is more severe when digesters are heated. To solve the problem it is essential to remove as much of the moisture as possible before the gas comes into contact with the gas system devices. For this reason, water traps should be located as close to the digester as possible. All piping should be sloped a minimum of 1% towards the water trap, which should be situated at a low point in the gas line.

Flame traps are emergency devices installed in gas lines to prevent flames travelling back up the gas line (flashback) and reaching the digester. The flame trap generally consists of a box filled with stone or a metal grid. If a flame develops in the gas line, the temperature of the flame is reduced below the ignition point as it passes through the trap and the flame is extinguished.

Pressure regulators are used when a lower pressure than the system operating pressure, is required for a specific device such as a boiler water heater or incinerator. Regulators maintain a constant gas pressure at the point of use

The rate of gas production is probably the most sensitive process control indicator at the disposal of the operating staff. Gas meters should be regularly serviced so as to give accurate and reliable gas readings. Every effort should be made to have the gas meter calibrated every six months.

Check valves (non-return valves) are installed in the gas line to allow gas flow in one direction only i.e. out of the digester.

Gas pressure gauges indicate the pressure in the gas system and assist in locating any blockages in the line. If a blockage occurs, a pressure reading downstream will register a lower pressure than that of a gauge upstream.

The pressure relief device at the waste gas burner safely flares excess gas to the atmosphere and thus reduces the potential for a dangerous accumulation of gas in the system.

Many anaerobic digestion waste treatment plants have a means of storing excess gas. This can be in the form of either a floating roof on the digester or a separate gasholder.

A mixture of biogas and air can be explosive. Methane gas in concentrations of between 5% and 15% in air by volume is explosive. Operating staff on waste treatment plants should ensure that no air is allowed to enter the digester or gasholder. All piping and equipment must be sealed properly to prevent gas from escaping to the outside. There must be no smoking and all electrical installations, including light switches, torches etc must be of the explosion-proof type, as the smallest spark could ignite escaped gases.

Michael Russell

Your Independent guide to Waste Treatments [http://waste-treatments.com]