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 or inclined robust mixers. The 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

A feature of high-load biogas reactors is high-solid content in the reactor up to 16%. The mass is so thick that a stone weighing 10 kg does not sink on the surface immediately. The organic dry matter load is 8-15 kg per m3 of reactor per day, which is twice to three times as high as that of a reactor with the CSTR biogas technology.

To mix the thick mass, patented high-load mixers are used which allow hot repairs without shutting down the reactor.

Fermentation occurs in the thermophilic mode of +44° to +55° С. In this mode, operation is safe during the summertime. Unlike a CSTR biogas reactor, the high-load reactor does not need to be heated but instead, to be cooled as required. A higher operational temperature provides a deeper substrate decomposition resulting in a greater biogas output.

Due to the high load of the reactor, the capital costs are reduced by 2-3 times compared with the CSTR technology. These biogas plants are very robust, and particularly well-suited for high-calorie raw materials such as maize silage or grass.

Distinctive features:

  • high organic load 8-15 kg organics per m³ of reactor per day
  • high solids content in the reactor 14-16%
  • thermophilic modes +48° to +55° C
  • not only heating, but also cooling of the reactor
1 to 30 MW
power capacity

Suitable substrates:

  • maize silage and Napier grass
  • sunflower pressed cake
  • straw, husks and pellets
  • brewery spent grain, draff
  • fruits and vegetables, waste
  • sugar beet pulp, potato pulp, tapioca pulp
  • condensed syrup from ethanol distillery
  • marc from starch production

Realized objects

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Seelow

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Teofipol-2

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