Improving the operation of old biogas plants

Most of biogas plants in the world were built 10-15 years ago. At that time, old CSTR technologies were used. Now a new modern technology of high-load reactor (HLR) has appeared, which makes it possible to increase the old reactor capacity sometimes even upto 3-5 times. In an old CSTR technology, the organic dry matter load ODM is 2-5 kg / m3 of reactor volume per day. In the HLR we achieve the load of 12-16 kg ODM / m3 reactor per day. And this is without significant changes in the plant design. 

If the feedstock is of different types, we can play with technological regimes. Sometimes we can achive double-tripple biogas outputs without any changes in equipment but with small changes in piping.

Often, old plants are equipped with weak mixers and a simple addition of one or two mixers gives 30-100% increase in production.

It is also often the cause of poor fermentation that the bacteria are not supplied with the right micronutrients. Our trace elements are offered in a special form and do not sediment. 

In the old days, biogas plants were built with post-digesters, which cost the same as a main reactor, but give only 5% of biogas. We can convert the post-digesters into full-fledged reactors and thus double-tripple the productivity.

If you have a 10-15 years old biogas plant operating with maize silage or a 3-5 years old CBG plant using Napier grass, we are 100% confident that we will tripple its capacity with the existing reactor volumes. At the same time, more raw materials are needed to produce more biogas and energy. But the cost of such reconstruction is several times cheaper than building a new reactor.

We are confident in what we offer here.The consultancy is not that expensive. You give us basic information about your plant, drop a couple of drawings, perhaps we visit your plant and than provide our plan.

If you became interested in our ambitious proposal please contact us biogas@zorg-biogas.com