BIO-WASTE PROCESSING INTO BIO-HUMUS AND BIOGAS

Biogas plant for agricultural waste processing with producing power, heat and bio-fertilizer

RUSSIASAINT-PETERSBURG

2

PROBLEM

According to calculations made on the value of the popular equivalent, without-litter manure/dung is 10 times more dangerous on the level of chemical pollution than municipal waste.

Without-litter manure/dung is classified as unstable organic contaminator and, according to the World Health Organization, is a factor in the transfer of more than 100 different kinds of animals and humans diseases.

The search of effective ways of recycling in the food and agricultural industry is a very urgent

Poultry of medium efficiency(40 thousand laying hens or 40 million

chickens) annually

fromfrom 40 40 up toup to 83 83 thousands thousands tones of tones of

manuremanure

More thanMore than 400 400 thousandsthousands mm33

of sewage with high of sewage with high concentration concentration

of organic componentsof organic components

PigPig--farmfarm of medium efficiencyof medium efficiency(4 500 (4 500 animalsanimals))

annually175 175 thousands thousands tones tones

of manure sewageof manure sewage

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PURPOSE

Waste recycling Biogas receiving Bio-humus receiving

Chicken manure

Liquid dang of livestock

Liquid pig dang

Grass

Sewage sediments

Waste fats

Biogas is the gas consisting mainly from:70-75 % methane (CH4)30-25 % carbon dioxide1,5-2 % other gases (ammonia, hydrogen, hydrogen sulfide)

The results of biogas processing are:

1. Heat (hot water,heating of residentialand industrialobjects)

2. Electric power(1kub.m gas = 2 kW)

3. Automobile fuel

Receiving of bio-humus in a short time - 2-3 weeks.Natural bio-humus contains biologicaly active substances (nitrogen, phosphorus, potassium), macro- and microelements. Advantages of bio-humus :-- Maximum preservation and accumulation of nitrogen

- The absence of pathogenic

- The high level of organic matter humification

- Resistance to leaching of soil nutrients. No need in additional introduction of bio-fertilizers for 5 years

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ADVANTAGES

Flexibility: suitable for large enterprises and for small farms. The plant can be designed with the capacity: 5, 10, 25, 50, 100 … 350 tones daily

Efficiency - low cost due to unique design solutions, lowing energy and resource demanding

Unification - using demountable elements

Easy-montage - short time to frame

Multi-resourced - using of any cattle or birds manure as well as waste oil and grass

Environmental friendly - bio-humus 3 times increases crop capacity without nitrates

Automation - all processes are controlled automatically

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TECHNOLOGY

Biogas is produced under the anaerobic conditions in a multistep process of fermentationor expansion. For the industrial production of biogas the complex technologies was developed including the following components: biomass accumulator tank, hydrolysis reactor, methane tank (fermenter) in which the digestion takes place, gas tank with gas cleaning system, cogeneration unit.

Receiving tank Hydrolysisreactor

Autoimmunizationunit

Heating system

FermenterGas holderCogeneration

unit

WarmthHot water

Electricity

Bio-humus

Bio waste

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RECEIVING TANK

The bio-waste goes to the receiving tank, where the homogenization takes place. The substance is carefully mixed and stabilized by acidity and temperature mode.

The receiving tank stays open only for solid fraction loading

The pumps and other receiving equipment provides both homogenization of the mass and tits transferring to the hydrolyze tank.

The capacity of the tank is enough for 2-3 days.

With standard solution the tank is dug for the convenience of filing with the solid fraction of the substrate.

View of the receiving tank

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REACTORS

From the homogenization tank the bio mass goes into the hydrolyze reactors and then to the fermenter (meta-tank). In these reactors the substrate fermentation takes place when heated to temperatures of mesophilic regime. Temperature and the level of the substrate in the reactor are maintained automatically.

Reactors (hydrolyser, meta-tank) are placed at the prefabricated basement providing easy leading of engineering facilities and all construction is easy assembled. The walls and the roof of the tank are made from prefabricated sheet constructions which should be connected hermetically.

The inner side if metal is fettled by special acid-proof composition. The reactors are fully hermetic and gastight, doesn’t need installation gasholders at the top of the reactor.

Concrete is not used as the constructive material.

Tanks construction

Ready-assembled tank

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ENGINEERING FACILITIES

Heating the reactor is made from dual-fuel boiler by antifreeze through the floor heating and wall receptacles. Fuel for the boiler at the launch stage is chosen according to specific conditions (solid, liquid fuel, gas).

Thermal insulation of walls is made by ready mats. Maintaining of the desired temperature is carried out automatically with a programmable controller based on indicators of temperature sensors installed inside the reactors.

Method of substrate mixing and its supply from hydrolysis to meta-tank is hydraulic. Mixing modes and the yield of biomass are programmed and is executed automatically.

Heating, ventilation, hot and cold water are made by the scheme outlined in the draft, based on the specific terms.

Mixing of the substrate is carried out by pumps, located outside the reactors. Operating the valves and pumps is produced automatically by the controller. Tanks heating system

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GAS EQUIPMENT

Biogas has a stage of cooling, impurities removal, and is compressed to the pressure of 0,8-1 Bar, which is maintained automatically in the medium-pressure gas-holder. Biogas goes into the boiler room through the pipeline, where at the gas distribution point the pressure is lowered to the desired value.

The biogas emitted in the fermenter is collected in gasholder, the it is cooled and passes several filters for cleaning from the admixtures of hydrogen sulfide and reducing of carbon-dioxide gas percentage. Further biogas is pressed for the pressure needed for stable work.

The pipeline brings biogas into the boiler room, where at the gas distribution point it is lowered to the pressure required to operate the reactor and the co-generator. This ensures stable operation of devices, regardless the uneven emission of gas in a reactor.

Gas cooling and filtering system for biogas

water

Electricity Steam/hot water

Hot water

Gas Cleanwater

Cooling system

MotorGenerator

Utilizing tank

Radiator

Exit gas

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КОГЕНЕРАЦИОННАЯ УСТАНОВКА

View of the co-generating unit

Scheme of co-generating unit

The biogas produced in the reactorgoes to the gas-piston installation producing electricity.

Heat is a byproduct ofelectricity production.

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THE OUTER CUPOLA

A distinctive feature of the biogas plant is the presence of an additional heating cupola, provides a positive temperature circuit inside the unit, which allows laying all communications at no extra cost, and also gives a beautiful appearance to the plant. Also supplies the conditions for chicken farms waste recycling without adding any organic or non-organic extras. As the result the received bio-humus is ecologically clean and can be used in the agriculture.

All manufacturing and technical facilities are placed under the cupola. The whole biogas plant (excluding the gasholder of the middle pressure) is placed under the light cupola provides positive temperature in the cold season.

Thus solution cheapens civil works and allows refusing the container version of gas-reciprocating machine which reducesthe cost of laying of facilities.

All elements are easy-demountable.

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PROJECT OF BIOGAS PLANT WITH THE CAPACITY OF 25 TONES OF MANURE DAILY

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PROJECT OF BIOGAS PLANT WITH THE CAPACITY OF 50 TONES OF MANURE DAILY

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PROJECT OF BIOGAS PLANT WITH THE CAPACITY OF 80 TONES OF MANURE DAILY

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ECONOMY INDICATORS

Chicken manure , 1 t

Liquid dang of livestock, 1t

Liquid pig dung, 1t

Grass, 1 t

Waste fats, 1 t

BIO WASTE БИОГАЗБИОГАЗ ELECTRICITYBIOGAS BIO-HUMUS

90 m3

60 m3

60 m3

650 m3

1250 m3

180 kW

120 kW

120 kW

1300 kW

2500 кВт

0,85 t

0,70 t

0,70 t

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16 RUSSIA, Saint-Petersburg,Ligovsky pr., 254Tel. 7 (812) 458-85-73, 458-85-74

www.polyinform.comE-mail: info@polyinform.com

BIOGAS PLANTSBIOGAS PLANTS AREARE

INNOVATIVE SOLUTIONSINNOVATIVE SOLUTIONS

IN THE FIELD OF AGRICULTURALIN THE FIELD OF AGRICULTURAL

WASTE RECYCLINGWASTE RECYCLING