High-load reactors

High-load
reactors

Substrate loading

A frontal loader delivers substrates into the hopper where they are crushed and fed to the horizontal auger. Next, the substrates are transported to the vertical auger.

Supply of substrates

Substrates are fed into the reactor with vertical and inclined augers.

Heating

The set temperature inside the reactor is maintained with heating pipes on the inner reactor walls.

Mixing

The substrate is periodically mixed using the vertical paddle mixers. The paddle mixers have been specially designed for mixing a thick and viscous mass.

Digestion

Anaerobic bacteria digest the substrates, producing biogas.

Cooling

In the summer, the reactors are not heated but cooled instead.

Biogas collecting

Biogas is collected under the roof or stored in a gasholder

Biogas conditioning

Biogas is dried in a chiller and compressed by a gas blower. Sulfur is removed by means of an activated charcoal filter. Cleaned biogas is pumped for combustion

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01
Substrate loading
02
Supply of substrates
03
Heating
04
Mixing
05
Digestion
06
Cooling
07
Biogas collecting
08
Biogas conditioning
09

Technology Description

The high-load reactor is a breakthrough biogas technology, a game-changer. Zorg Biogas offers a product the only of its kind. Due to the high load, the volume of the reactor and the capital costs are reduced by 3 times compared to the old mass-market CSTR technology. For the solid and high-calorie raw materials like maize silage or Napier grass, HLR is truly the best available technology.

A feature of high-load biogas reactors is high-solid content in the reactor up to 18%. The mass is so thick and viscousious that a stone weighing 10 kg does not sink immediately. The organic dry matter load is 8-15 kg per m3 of reactor per day, which is 3 to 5 times higher than that of a CSTR reactor 3-5 kg.

Distinctive features:

  • load 8-15 kg organic dry matter / m³ of reactor / day
  • high solid content in the reactor 18%
  • HLR reactor is 3 times smaller and 2 times cheaper than CSTR
2 to 30 MW
power capacity

Suitable substrates:

  • maize silage
  • Napier grass
  • condensed stillage from ethanol distillery
  • stems from starch production
  • sugar cane, cassava tapioca, triticale, amaranth, sorghum
  • straw pellets, sunflower pressed cake

Realised objects with HLR technology

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Teofipol-2

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TEOFIPOL-3 and -4. The biggest biogas plant in the world!

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