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Products of PlanET Biogastechnik - Best Quality and TechnologyThe Alpha and Omega of Biogas TechnologyPrOducTsPrOducTsPlanET Biogastechnik – Everything from a Single SourcePlanET Biogastechnik GmbH is one of the world’s leading biogas plant suppliers. Founded in 1998, the company’s service portfolio covers all fields of biogas technology and component distribution: from planning, plant construction, refinement of biogas to natural gas quality and all the way to service and biological support from our in-house laboratory. PlanET’s RePowering division enables customers to increase the efficiency of their existing plants in a targeted fashion. At the same time, the modularly developed SYSTEMBIOGAS functional principle allows biogas plant operators and investors to react to new developments on the biogas market at any time. Over 200 employees currently work at the company headquarters in Münsterland alone. Other employees work in the international subsidiaries in the Netherlands, France and Canada. We are also represented in the United Kingdom, Italy, Spain and Japan. PlanET already has successfully realised more than 300 biogas plants worldwide on a scale from 40 kW to several megawatts.Page 2charging Technology• PlanET Vario 04• PlanET eco® flow 06• PlanET RePowering Charging Technology 07• PlanET Bio Mix 08Micro-crushing Technology• PlanET Gorator® 10• PlanET DesiUs 12Fermentation Process Technology• Pasteurisation Container 14• Concrete Tanks 16• Compact Manifold 17• PlanET eco® Mixing Technology 18• PlanET eco® cover 20• PlanET eco® cover plus 21• Air-Supported Roof 22• Control Technology for Direct Marketing 24• Emergency Capability 25• Technical Container 26• PlanET Separator 28• Gas drying 29Gas Technology• Combined Heat and Power (CHP) 30• Biogas Flare 32services / Information• PlanET Biological Laboratory 34• PlanET Biomethane 36• PlanET Biogas Plant Efficiency 38• Survey Results 40contentPage 3PlanET VarioThe Most Flexible Feed system Module on the MarketThe PlanET Vario can convey chopped energy crops, solid manure, feed remains as well as solid coferments such as old bread directly into the fermenter. The modular system offers containers from 11 to 120 m³, which can also be expanded subsequently. Thanks to PlanETs Vario conveyor technology, the plant saves energy and keeps wear to a minimum. The conveyor lines are made entirely of stainless steel, propelled individually and fit with side flaps so that the substrates can be transported effectively. The front side is fitted with an opening cylinder and auger system which transports the substrate into the digester. A current survey conducted by the German open Business School in Ahaus made it clear: The modular expandable all-rounder received the top marks. Due to these exceptional survey results, PlanET Biogastechnik is offering you a five-year guarantee for the PlanET Vario’s conveyor lines as a highlight. After all, our customers have absolutely assured us: PlanET Vario technology is unbeatable and dependable in daily use. The Benefits at a Glance:• conveyor system made entirely of stainless steel and high quality plastic in the substrate area• base module made of stainless steel; all modules are available in stainless steel as an option• the conveying strings can be installed on a concrete floor• future-proof investment – expandability thanks to modular construction • low susceptibility to failure; simple and reliable components• extremely maintenance friendly; individual elements can be shut down separately• uniform discharge, resulting in a good fill level for the augerPage 4Technical data & InformationenGeneral data (different sizes upon request)volume holding container in m3 11 16 21 28 38 50 55 74 120empty weight in t 2,9 3,6 4,4 4,8 6,5 7,0 8,0 8,8 12,4maximum payload in t (depending on the equipment package)6 8 16 21 28 38 41 56 90dimensionslength (A) in m 4,66 4,66 4,66 4,66 7,59 7,59 7,59 7,59 13,5width (B) in m 3,57 4,27 4,97 4,97 4,97 4,97 4,97 4,97 5,67height (C) in m 2,45 2,45 2,45 3,15 2,45 3,15 2,45 3,15 3,15Holding system PlanET Vario conveying technology• separate hydraulically driven conveying strings• efficient conveying through hinged flaps• hydraulic with electrical switching• loosening auger 1.5 kWcontrol system Electrical panel with industrial PLc• wiring ready to connect• manual and automatic operation possible• interfaces for status messages and remote start (ProfiBUS possible)Further Advantages • expandable to up to 120 m³ thanks to modularity• operational safety• optimised emptying also with diffcult substratesExtras • holding container available completely in stainless steel• weighing system with large display• 2nd looseing auger for up to 70 % manure and grass• lid available to reduce rain water entrycharging Technology Multirotor 360horizontal auger 7,5vertical auger 5,5charging auger 2,5Multirotor 450horizontal auger 7,5vertical auger 6,8charging auger 3,6drive in kWauger diameter in mm 330 280 360max. throughput maize silage in t/h 10 - 12 8 15Technical drawing:Page 5PlanET eco® flowThe Liquid Flushing system for the PlanET VarioThe PlanET eco® flow is a liquid flushing system with an progression cavity pump, perfectly tailored for combine use with the PlanET Vario. Liquid flushing provides you with great flexibility in selecting substrates and makes it possible to mix the tank contains extremely thoroughly. The mixing pump is operated continuously. The feed pump is equipped with a speed regulator which adjusts the feed rate in the pipeline under constant flow pressure. The feed screw also has a speed regulator to ensure variable solids feeding in the chute. Remote installation of the PlanET eco® flow is possible, as is the feeding of multiple fermenters. The liquid flushing system minimises wear, resulting in a long service life.The Benefits at a Glance:• liquid flushing system with progression cavity pump• great flexibility in substrate selection• control and regulation from a single source• low energy consumption demonstrated in practical tests• additional integration of the PlanET Gorator® is possiblePage 6Fermentation Tanks with concrete covers? No ProblemThe New control unit PlusOld Feed Auger, New Feed systemCoupling pieces make it easy to connect the PlanET Vario to conventional auger systems available on the market. This includes mechanical adaptation and electrical connection.The PlanET Vario can be installed on top of the fermentation tank in the case of fermenters with concrete covers. In this case, the auger is run into the tank from the top through the fermenter cover and ends below the fill level.In addition to the standard control units for the input augers NawaRotor, MultiRotor and PlanET eco® flow, the Control Unit Plus is now available as well. The Control Unit Plus provides plant operators with a greater scope of functions, as well as more possibilities of monitoring and setting control functions. The internal database can be read via network. The Control Unit Plus is a self-contained system with a Profibus interface, teleservice, database and network connection.Page 7PlanET rePowering charging TechnologyThe Best solution for 100 % ManureThe PlanET Bio Mix is a special feed system which is able to grind up and mix substrates such as energy crops and especially manure ahead of time. The use of one frequency converter and one motor per mixing screw makes it possible to adjust the mixing screw in relation to the input material, thus minimising energy consumption. The mixing tub is made of stainless steel as a standard feature in areas susceptible to corrosion, ensuring reliability even after years of use. The feeding process is conducted uniformly into up to two fermentation tanks by means of a three-piece auger system (MultiRotor).PlanET Bio MixThe Benefits at a Glance:• robust feed system design based on years of experience • mixing tub made of stainless steel in areas susceptible to corrosion• all other component made of St 52-3 steel (1.4301)• the entire feed tank is optionally available in stainless steel• the feeding process is carried out by a low-wear MultiRotor auger made of stainless steel• optimised auger transitions to prevent material congestion• one gear, motor and frequency converter per mixing screw, meaning that all components can be controlled individually • complete control unit including signals for connection to the superordinate control unitPage 8Technical drawing:General data (different sizes upon request)volume holding container in m3 12 16 30 50average power consumption during normal operation in kW20 - 30max. throughput maize silage in t/h 8 - 10dimensionslength (A) in m 3,9 4,2 6,6 9,0width (B) in m 2,45 2,5 2,5 2,45height (C) in m 2,6 3,0 3,0 2,95Holding system Mixing Hopper with Vertical Mixing screwsdrive in kW 1 x 22 1 x 30 2 x 30 3 x 30control system Electrical Panel with Industrial PLc• Ready to connect wiring• Manual and automatic operation (industrial PLC)• Interfaces for status signals and remote start (ProfiBUS available)• Frequency converter 30 kWFurther Advantages • Mixing tub of stainless steel by standard• Mixers optimised to minimise power consumption• Mixing only in lower part of the hopper• Charging into 2 digesters possibleExtras • Mixing screws as extra strong “muck“ version for complete homogenisation of the hopper content• Hydraulical remote controlled lid available optionally• Load cells for weight proportional feeding, data transfer to control system• Mixing augers and upper part of hopper optional of stainless steelcharging Technology Multirotor (different sizes)drive in kW horizontal auger: 2,2vertical auger: 5,0charging auger: 2,5auger diameter in mm 350 The specific weight of the substrate modifies the throughput, higher feed line for moist material.)Page 9Technical data & InformationenPlanET Gorator®The High-Performance development in the Field of Micro-GrindingThe PlanET Gorator® grinds, shreds, mills, mixes, homogenizes and conveys – in short, it conditions your substrate in many different physical and mechanical respects. The decomposition of the organic material in your biogas plant primarily depends on the surface of the material, i.e. the surface of attack for the bacteria. This makes the PlanET Gorator® a suitable instrument for increasing the quality and quantitative of the gas yield. Micro-grinding has proven itself as a worthwhile investment with a retention period of less than 70 days, a manure or grass proportion of over 30 percent, or long-fibred substrate. Wet grinding has the added advantage that the wear and operating current on agitators and pumps is reduced so that your biogas plant works more efficiently, thus reducing operating costs. PlanET is now offering you a unique guarantee of satisfaction for the PlanET Gorator® – because we are thoroughly confident of our products’ performance.The Benefits at a Glance:• enlarges the material transition surfaces in the substrate• increases gas yield • mobilises enzymes and trace elements• reduces the viscosity and homogenisation of the substrate• reduces internal power consumption in the biogas plant• reduced quantities of substrate, lower operating costs.• no additional pump necessaryPage 10A diagonal disc rotates inside a cylindrical housing; the resulting tumbling motion accelerates the substrate in the axial and radial direction. The overlapping movements of the material create transverse and shear tensions which result in more intensive mixing and conveyance. Solids are transported into the radial and axial grooves and ground up by the tooth geometry of the diagonal disc. The substrate receives centrifugal acceleration and is pumped out of the pressure nozzle with the PlanET Gorator®.Throughput: 3 - 50 m3/h• Depending upon DM concentration and fibre content of the substrate, i.e. with dry matter (DM) of 8% throughput 40-50 m³/hPower supply: 22 kW• Power consumption depending upon DM and fibre content, i.e. with 8% dry matter (DM) 15 kWThe PlanET concept:For use with long-fibred material which is difficult to ferment, such as manure or grass silage.• First step: The bacteria decompose the substrate in the fermenter – natural organic decomposition is a fundamental prerequisite for the efficient operation of your biogas plant.• Second step: Integration of the PlanET Gorator® for material which is difficult to decompose or in the case of short hydraulic retention times.Page 11Technical data & InformationenPlanET desiusIncrease Your Biogas Yield with ultrasoundThe PlanET DesiUs functions using ultrasound. The sound waves generate extremely great heat and enormous pressure, which causes the plant cell walls to burst, thus releasing liquid. This technology improves the fluidity, which relieves the burden on the agitators, thus saving energy. However, its most important effect is that it dramatically increases the biological performance in the fermenter, thus increasing gas yield and plant efficiency. In contrast to the PlanET Gorator®, ultrasound treatment provides high efficiency for short-fibred substrates with a retention time of less than 70 days and a low proportion of manure and grass (under 30 percent). PlanET is now offering you a unique guarantee of satisfaction for the PlanET DesiUs – because we are thoroughly confident of our products’ performance.The Benefits at a Glance:• increases the biogas yield by up to 25 %• provides the same performance while reducing substrate feed• reduces fermentation duration by up to 15 %• reduces the viscosity and homogenisation of the substrate• reduces internal power consumption in the biogas plantPage 12Ultrasound treatment accelerates the anaerobic conversion of the fermentation substrates. In addition, it decreases the energy expended for the agitators by reducing the viscosity of the substrates. This means that conducting the ultrasound treatment is virtually energy-neutral. The PlanET DesiUs can be flexibly adapted to the existing process technology in consideration of specific substrate properties.Technical features• Treatment of substrates with solid material content of up to 10% dry residue• 2000 W ultrasound performance per flow cell • Easy to adapt to changing feed quantities• Optional mechanical pretreatment• Allows incremental viscosity reduction• Compact configurationPage 13Technical data & InformationenPasteurisation containerMore Performance for cofermentation PlantsPasteurisation is an essential step with cofermentation plants which ferment animal slaughter waste and by-products as well as food waste. Conferments are usually high-energy substrates with a relatively high proportion of fats and sugars. The use of coferments can achieve a high gas yield with the same or smaller fermentation paths, since they ferment much faster than energy crops or manure, for instance. Before being fed into the biogas plant, the liquid coferments are heated up to 70°C and kept at this temperature for a duration of 60 minutes without interruption. Once this retention time has elapsed, the input materials are pumped into the fermentation tank by a rotary piston pump. Like with renewable resources, coferments can also be used as high-grade fertiliser on arable farmland after being fermented in the biogas plant.The Benefits at a Glance:• the pasteurisation process is conducted intermittently in batch processes.• a slow-running agitator prevents caking and keeps sediments suspended• the substrate flow can be divided up amongst several different fermentation tanks• an intelligent control unit logs the individual cycles• protects protection against overflowing and overfillingPage 14The PlanET pasteurisation unit is available in two performance sizes, each of which fits into one of the 6-metre containers which is preassembled at the PlanET workshop.Supplementary pateurisation components include a heated pre-tank and grinders. The substrate is heated to up to 25°C in the pre-tank, which keeps it fluid and increases hygienisation performance. Grinders can be used in the substrate feed for pasteurisation depending on the type of coferments being fed.LeckerkennungsfolieDrainagePasteurisation 12 m³/d - Profi• 1 pasteurisation tank à 2 m³• manual gate valvesPasteurisation 12 m³/d - Premium• 1 pasteurisation tank á 2m³• pneumatic gate valve • an additional hygienisation tank can be installed• distrubution of substrate between different digesters possiblePasteurisation 24 m³/d - Premium• 2 pasteurisation tanks á 2 m³• pneumatic gate valves • distrubution of substrate between different digesters possiblePage 15Technical data & Informationenconcrete TanksPlenty of room for Your substrateThe tanks form the basis for the long-term effectiveness and efficiency of a biogas plant. PlanET biogas plants are based on monolithic reinforced concrete tanks which are poured on-site and configured to meet the specific requirements of the site in question. Reinforced concrete has proven itself as a base material in fermenter construction thanks to its long-term structural integrity and flexibility. Our reinforced concrete tanks are designed in accordance with the latest standards and recognised rules of technology.The concrete-encased heating lines ensure suitable concrete core temperature and optimal biological process conditions in conjunctions with heat insulation.The sizes given are sample fermenters, different sizes upon request. Prestorage tanks are available in sizes 8 by 3 m and 10 by 4 m.Volume Overview PlanET Fermenters (gross)H Ø 12 m 14 m 18 m 21 m 23 m 25 m 28 m 30 m 32 m 34 m6 m 678 m3 923 m3 1.526 m3 2.078 m3 2.492 m3 2.945 m3 3.694 m3 4.241 m3 4.825 m3 5.447 m38 m 904 m3 1.231 m3 2.035 m3 2.770 m3 3.323 m3 3.926 m3 4.926 m3 5.654 m3 6.433 m3 7.263 m3The Benefits at a Glance:• tanks made of quality-controlled reinforced concrete • conical base plate• heating encased in concrete• floor/wall insulation (WLG 035)• large stainless steel pressure-resistant door for maintenance and inspection work• watertight reinforced concrete in accordance with DIN 11622 and DIN 1045-1Page 16compact Manifold safe, speedy and simpleThe PlanET compact distributor is a modularly configured pump distributor consisting of a distributor block, a rotary piston pump and suitable slide valves (manual or pneumatic industrial slide valves). A flow meter (available separately) can be installed to record the material flow quantities. Substrate can be sucked out of three to six tanks and pumped accordingly using the rotary piston pump suitable for clockwise and counter-clockwise rotation. Subsequent expansion to connect additional tanks is also possible, meaning that a pump concept adapted for each operation can be created. The compact distributor is a module of the SYSTEMBIOGAS developed by PlanET.The Benefits at a Glance:• virtually odour-free slurry transfer from one tank to the next• compact configuration (h=1.5 m / w=1.4 m / l=2.7 m)• robust rotary piston pump• “suction” and “pressing” selectively from a single line• 3 to 6 tanks can be connected• corrosion-free stainless steel pipelines• choice of pneumatic industrial slide valves or easy-moving manual slide valves• internal or external control unit as requestedPage 17PlanET eco® Mixing TechnologyWell Mixed is Half FermentedThe right selection of agitator technology makes an important contribution to achieving the best possible gas yields. You won’t achieve satisfactory plant efficiency without ideally configured agitator technology. You can only get the most out of your plant if the fermentation substrate is mixed homogenously – and this is only possible when the agitators match the tank size and substrates. The patented PlanET eco® agitator series offers you all time-tested agitator technologies, from submersible motors to large-wing and paddle agitator – all of which feature economical internal power consumption. And always durable and wear-resistant.The Benefits at a Glance:• optimally configured agitator technology in your biogas plant• agitator components developed based on experience• high and low speed• durable, energy-efficient and wear-resistantPage 18PlanET eco® mix• low energy consumption of max. 7.5 kW, 3,000 Nm torque, 70 rpm• 1.4 m blade diameter, • great propulsive effect for high dry matter contents• laterally and vertically adjustable• mixing process which preserves bacteria and prevents sinking layersPlanET eco® prop• max. 5,7 kW output, 5,000 Nm torque, 40 rpm• 2.5 m blade diameter• ideal thorough mixing thanks to great shear forces • prevents sinking layers• optimal for the widest variety of input materialsPlanET eco® turbo• max. 13 kW output, 365 rpm• 0.7 m blade diameter• flexible use, laterally and vertically adjustable• effective for breaking up floating layers• low-wear direct drive without gears• Long service lifePlanET eco® paddel• suitable for long-fibred materials up to 12 % dry matter content in the tank• slow-speed with max. 15 kW output, max 11 rpm• 4 m blade/paddles diameter• frequency converter guarantees low power consumption • diagonally positioned paddles ensure optimal mixing• breaks up floating layersPlanET eco® stabmix• max. 22 kW output, 10,000 Nm torque• propelled by frequency converter• installed in tank wall• stageless inclination adjustment for the agitator• installed on anti-vibration bearings on extension mountPage 19Technical data & InformationenPlanET eco® coverdesulphurisation with close-Meshed FabricPlanET eco® cover polyethylen (PE) fabric combines various properties for achieving optimal biogas plant operation. This is not a conventional net, but a very close-meshed fabric. The biogas is desulphurised in the fermenter by means of a biocatalytic procedure using air injection. The fabric’s great surface area (much greater than that of the previous wooden ceiling) offers an ideal habitat for the bacteria which desulphurise the gas. In addition, the PlanET eco® cover serves as a thermal barrier and support for the gas holder membrane.The Benefits at a Glance:• greater desulphurisation area than with the wooden ceiling • very resilient materials made of PE or V4A (stainless steel)• flexible and resistant to chemicals – no wood in the fermentation tank• good thermal barrier; no additional insulation necessary• revision work in the tank can be conducted from the PlanET eco® cover• structurally configured up to snow load zone 3 (= 1.10 kN/m2) • protected as a utility modelPage 20Fermenter desulphurisation with Non-Woven FabricThe PlanET eco® cover plus is the enhanced version of the PlanET eco® cover. The non-woven fabric has the properties of even greater thermal insulation and desulphurisation performance.The desulphurisation fabric is optimally stretched over the fermentation tank with tension belts which were specifically developed for this application. The stainless steel column in the centre of the tank provides an additional point of support and simultaneously serves to deflect the belts. The belts are fastened to the exterior wall of the fermentation tank by patented anchor elements made of stainless steel.PlanET eco® cover plusThe Benefits at a Glance:• even greater desulphurisation performance than the PlanET eco® cover• very resilient materials made of PE or V4A• flexible and resistant to chemicals – no wood in the fermentation tank• even better thermal barrier than the PlanET eco® cover• revision work in the tank can be conducted from the PlanET eco® cover plus• structurally configured up to snow load zone 3 • protected as a utility modelPage 21Air-supported roofMore storage Volume for Your Biogas PlantThanks to their round shape, PlanET air-supported roofs possess a much greater gas storage volume than conical roofs do. But the shape isn‘t the only thing that offers considerable benefits – the film material is designed for durability and is reliably fastened to the plant by an innovative new sealing system – which is easy to maintain at the same time. The air-supported roof is executed and mounted to your biogas plant in time-tested PlanET quality through and through. In conjunction with the PlanET eco® cover or PlanET eco® cover plus, the roof is an absolute innovation in the world of biogas components. The shape and colour of PlanET air-supported roofs also blends harmoniously into the landscape. The roofs are available in dust grey or moss green upon request; the dust grey roofs offer even greater advantages in terms of solar radiation and heating.The Benefits at a Glance:• five years warranty worldwide• up to 20% more gas storage volume• the compressed air in the sealing hose is divided into two semi-circles, meaning that only one side of the roof has to be opened during maintenance work• fan unit completely embedded in PE; safe from corrosion and external influences• storm-proof up to wind strengths of 12 on the Beaufort scale (hurricane)• particularly sturdy 900 g/m² weather protection foil• two standard colours which blend in well with the environment: dust grey and moss greenPage 22sealing systemThe special feature of the innovative new sealing system is the two compressed air circles of the sealing hose. This makes it possible to keep one semi-circle of the tank pressurised during maintenance work, which makes it easier to conduct inspections more quickly. The compressed air monitoring unit is installed in the heating cabinet or interspace, protecting it from frost. This ensures ideal protection, even in the cold and stormy season.Fan unitThe fan unit is made of PE, making it especially durable and UV-resistant. The fan is explosion protected and mounted directly above the work platform so that it is easily accessible for maintenance. This way, the installation position reduces the explosion zone of the gas storage. Less foreign matter and fouling gets into the system thanks to the high installation position. The new development of the throttle valve on the air supply unit allows active control of the gas storage fill levels, thus increasing the effectively usable gas storage volumes, enabling gas storage management.reinforced MaterialIn contrast to conventional air-supported roods, we use a particularly durable PVC weather protection foil with a thickness of 900 g/m² (competitors often use a foil thickness of only 680 g/m²). This means that the roof is approved for hurricane wind strengths of 12 on the Beaufort scale. The PE gas storage foil is particularly durable and impermeable to odours.stainless steel seal and sealing HoseThe stainless steel seal rail can be used flexibly. It can be used as a mount for the new PlanET air-supported roofs as well as for single-layer roof systems. The grey EPDM sealing hose can still maintain clamping force under heavy solar radiation, since the material reduces the surface temperature.connection FlangeAnother new item is the design of the connection flange for the fan unit and the cross-ventilation for the air-supported roof on the opposite side. The connection was designed to minimise the risk of the foil tearing thanks to a great number of fastening elements.Page 23Technical data & Informationencontrol Technology for direct MarketingThe right Technology for supplying Power as requiredThe plant control unit can generally be connected to supply power as required via DSL or mobile phone. A DSL connection is the first choice. The prerequisites you as the operator must meet merely lie in obtaining a set IP address, a data flat-rate and external availability for the network operator. The biogas plant reports its availability and gas fill level to the direct marketer. The power output is then determined and you will receive a report from the direct marketer indication whether your biogas plant (now a virtual power plant) is ready for operation and how great the output is. Additional features of the control technology installed by PlanET include malfunction alerts via fax, SMS, E-mail or telephone, as well as a live view of the plant situation. The control technology for direct marketing is simple and can be fitted to virtually any biogas plant.The Benefits at a Glance:• external plant control via DSL or mobile phone• automated biogas plant start-up and shutdown• easily retrofitted• low effort, great benefit• additional features such as automated malfunction alerts are also availablePage 24The solution for EmergenciesEmergency capabilityIn the event of a power failure, your biogas plant will grind to a halt, too. Moreover, power failures can lead to dangerous situations such as uncontrolled foam formation when mixing stops. In order to prevent this and avoid unnecessarily disturbing your biology, PlanET offers the integration of an emergency power switch in your (existing) biogas plant. An additional switch is installed which can be used to switch your plant over to back-up power in the event of a power failure. A small back-up power generator (approx. 21 kW) will then supply power to the agitator, air-supported roof, emergency flare stack and plant control unit. PlanET Biogastechnik’s product line includes a manual and an automatic module. With the manual module, the components to be supplied must be switched on by hand. The automatic back-up power module automatically recognises the need to switch over to back-up power and automatically controls the necessary biogas plant components with the plant control unit.The Benefits at a Glance:• easily retrofitted into virtually any control unit• continued supply of the necessary components• selection of manual or automatic back-up modules Page 25Technical containerEverything in One shortens construction TimePlanET Biogastechnik offers you complete technical containers as part of the modular SYSTEMBIOGAS. The use of this type of container reduces the construction time on site, meaning that the plant can be commissioned quickly. The technical container is assembled in our in-house workshop in Vreden and contains precisely the components which you need to ideally run your biogas plant. The container is then shipped out and connected. The container can easily be modified, retrofitted or converted at any time. The technical container supports the smooth operation of the plant. For instance, it makes for short line routes, simple heat distribution with low heat loss, as well as safe and weather-protected housing of the control cabinets.The Benefits at a Glance:• components are installed in the container at the workshop• trouble-free connection to existing plant components on-site• positive synergy effects thanks to standardised container variants• accepted by many banks as collateral for credit safeguardingPage 263 m (10 ft.) Technical container• 3 control panels• compressors3 m (10 ft.) Technical container• pumping station• compressors12 m (40 ft.) Technical container• 5 control panels• compact manifold• heat distribution (max. 550 kW)• compressors6 m (20 ft.) Technical container• compact manifold• compressors6 m (20 ft.) Technical container• 5 control panels• heat distribution (max. 550 kW)• compressors6 m (20 ft.) Technical container• 3 control panels• pumping station• heat distribution (max. 300 kW)• compressorsPage 27Technical data & InformationenPlanET separatorTake Advantage of Every Last Bit for Top EfficiencyMany operators of biogas plants have notices that they are able to quickly and conveniently transform their fermentation residue into high-grade fertiliser by using a PlanET separator. Nutrients produced this way in dry, low-odour form can be exported lucratively, especially in regions with little livestock. The fields of use consist of coarse particle separation before and after the fermenter as well as the option of follow-up treatment of the separated liquid with the Centrifugal Classifier Separator:The separated solids• dry matter can be regulated between 25% and 40%• solids are free of silage effluents and ideal for composting• low-odourThe seperated liquid• ideal for mixing processes before the fermenter• low storage space requirements thanks to volume reduction• no sinking or floating layers• no blocked lines• nutrient reduction while saving audit areaThe Benefits at a Glance:• nutrient export from the operation• prevents the need for an additional pasture lease• improves fluidity in the fermenter• no floating layers in the digestate storage tank• requires less energy for mixing• reduces storage costsPage 28dry Gas is the Way to GoCentral gas drying is a must for biogas plant operators who have one or several CHPs at the biogas plant site or who want to feed their biogas to a satellite CHP via long-distance lines. The biogas has to be dried before entering the lines in order to reliably prevent condensate from forming in the gas transport lines. Condensation drying cools the biogas down to 3-4 °C. Cooling down the gas condenses the moisture in the gas. After the gas drying process, the biogas is compressed and cleansed of hydrogen sulphide by an active carbon filter. The biogas can then be reheated for long-distance transport, so that it doesn’t have to be condensed again. PlanET offers the gas drying system in sizes 160 m3/h, 300 m3/h and 500 m3/h. The containers have the advantage of minimising temperature fluctuations, and the active carbon filters have a long service life thanks to their great filter volume. Gas dryingThe Benefits at a Glance:• fewer parts requiring maintenance• low costs of operation and maintenance • service conducted by PlanET• minimises temperature fluctuations thanks to installation in the container • the active carbon has a long service life thanks to its large filter volumes• the active carbon is easy to replacePage 29combined Heat and Power (cHP)Generate Energy and Heat EfficientlyBiogas is ideally suited for combustion in a combined heat and power plant (CHP) thanks to its relatively great proportion of CO2.At the same time, it is essential to differentiate between a gas-CHP and a pilot injection CHP. The special feature of gas-CHPs is the higher degree of thermal efficiency. That’s why they are mainly used for concepts with greater heating requirements, such as feeding into a local heat network, substrate drying or absorption cooling for gas treatment. The Benefits at a Glance:• big-name manufacturers in PlanET’s pool of suppliers (2G Energy AG)• the CHP is simple to integrate into your biogas plant• online tool for monitoring the individual CHP units• gas-CHPs are independent of markets and suppliers, since no additional pilot oil is necessary• gas-CHPs have a particularly high degree of thermal efficiencyPage 30Typecylindercapacity in lel. Power in kWel. Efficiency in %th. Power in kWth. Efficiency in %Overall Efficiency in %Power to Heat ratioTotal combustion in kWconsumption in m3 /h (at 50 % cH4 / *60 % cH4)Filius r06 6 i.R. 6,87 75 38,0 89 45,2 83,2 0,841 197 33,0*Filius 106 6 i.R. 6,87 100 38,0 121 45,8 83,9 0,829 263 44,0*Filius 206 6 i.R. 12,82 150 38,2 179 45,6 83,8 0,838 393 66,0*190 BGG 6 i.R. 12,82 190 38,0 221 44,1 82,1 0,861 500 100,0Agenitor 206 6 i.R. 12,82 220 40,6 232 42,8 83,4 0,948 542 109,0Agenitor 306 6 i.R. 12,82 250 41,0 265 43,5 84,5 0,944 610 122,0250 BGG 8 V 14,62 250 38,0 304 46,3 84,4 0,821 657 131,4Agenitor 208 8 V 14,62 265 40,0 298 45,0 85,0 0,899 663 133,0370 BGG 12 V 21,93 370 38,6 430 44,8 83,4 0,861 960 191,9Agenitor 212 12 V 21,93 400 40,1 445 44,6 84,7 0,899 998 200,0Agenitor 312 12 V 21,93 450 40,6 469 42,3 82,9 0,960 1.108 222,0Avus 500a 12 V 70° 29,20 527 41,1 527 41,1 82,2 1,004 1.282 214,0*Avus 500b 12 V 70° 29,20 637 40,4 675 42,8 83,2 0,940 1.578 263,0*Avus 800b 12 V 70° 36,66 889 42,0 875 41,4 83,4 1,020 2.116 353,0*Avus 1000b 16 V 70° 48,80 1189 42,1 1166 41,3 83,5 1,020 2.821 470,0*Avus 1500b 20 V 70° 61,10 1487 42,2 1458 41,3 83,5 1,020 3.526 588,0*Avus 500 plus 12 V 25,007 550 42,5 541 41,8 84,3 1,016 1.294 260Agenitor 406 6 i.R. 11,9 250 42,5 264 44,9 87,4 0,945 589 118MANJenbacherLiebherrPage 31Technical data & Informationencombustion Variant 40 m3/h 75 m3/h 150 m3/h 300 m3/h 500 m3/h 750 m3/h 1.000 m3/hThroughputmin. in m3/h 25 30 55 110 230 300 400max. in m3/h 40 75 150 300 500 750 1.000calorific Valuemin. in kWh/m3 4,5 4,5 4,5 4,5 4,5 4,5 4,5max. in kWh/m3 5,5 5,5 5,5 5,5 5,5 5,5 5,5Firingmin. in kW 170 170 270 600 1.035 1.400 1.800max. in kW 415 450 825 1.650 2.750 4.125 5.500sizesgas connection to gas fittings routeDN 150 DN 150 DN 150 DN 150 DN 150 DN 150 DN 150overall height in mm(top of foundation)4.000 4.000 4.500 5.000 5.500 7.000 8.000Fire tube length in mm 1.000 1.000 1.000 1.500 1.500 2.000 2.500Fire tube diameter in mm350 350 400 500 800 900 1.000Combustion conditions • exhaust gas temperature: 800 °C• semi-concealed combustion, visible flame• incl. flame view protection tubeSwitching system• Electrical cabinet made of plastic, including operation/malfunction display on burner control unit• Power supply via CEE electrical outlet (back-up power generator connected for emergency power operation) incl. phase reversing switch and diode for correct rotary fieldBiogas FlareBurn in case of EmergencyThe PlanET biogas flare is available in four “small” and three “large” combustion variants: 40 m3/h, 75 m³/h, 150 m³/h and 300 m³/h, as well as 500 m³/h, 750 m³/h and 1,000 m³/h. PlanET Biogastechnik offers biogas flares with semi-concealed combustion, meaning that the flame remains visible. Concealed combustion is also available for the “large” flares upon special request. The flare is made up of a burner and a stainless steel flare tube, a hot-dip galvanised stand console, gas fan, gas valve line, ignition device and switching system; weather protection housing is available as an option. The fan is connected upstream, so that reliable consumption is entirely possible, even under adverse weather conditions. The fan provides the minimum primary pressure of 25 mbar which this requires. The PlanET biogas flare is activated and deactivated automatically using external signals or internal pressure switches; the start-up process in accordance with EN 746 assumes the EN-approved burner control.The Benefits at a Glance:• automatic activation and deactivation• can be operated as a self-sufficient system thanks to integration into a separate gas take-off line• no under pressure in the system, fewer CHP failures• flare can still be operated in the event of a mains power failure if a back-up power generator is on hand• under pressure guard in the flare’s safety chainPage 32 Page 33Technical data & InformationenPlanET Biological LaboratoryKeep it Bubbling Away in the FermenterThe tanks and technology aren’t the only factors for successful plant operation. The actual players are the microorganisms which get the biogas process in gear. Samples are analysed and evaluated every day at the PlanET process laboratory. The results form the basis for optimal plant operation and quick commissioning. PlanET conducts the following examinations for you:standard Analytics:• pH values (hydrogen ion concentration)• EC value (electrical conductivity, salt content)• VOA (volatile organic acids)• TAC (buffering capacity)Additional Analytics:• Acid sample determination (acetic acid, propionic acid, butyric acid, isobutyric acid, valeric acid, isovaleric acid, caproic acid)• Dry matter• Organic dry matter• Ammonium-nitrogen (NH4-N)• Inhibition testFermentation substrate Examination:• pH value determination, dry matter content and organic dry matter determination and gas yield calculation• Fermentation test in accordance with VDI 4630 (duration: 4 weeks)• Calorimetric yield rate determinationcomplementary Materials for Process support:• Substrate S (mineral materials)Page 34The Biological ProcessHydrolysisEnzymes, fermentative bacteria (20 min - 24 h)fermentative bacteria (1-5 days)acetogenic bacteria(2-10 days)methanogenic bacteria (5-20 days)AcidificationAcetic Acid FormationMethane FormationPolymeric substances (long-chain compounds)Proteins, carbohydrates, fatssIMuLTANEOus FLOWservice-contract Biology:• PlanET regularly takes substrate samples and analyzes them in our own laboratory • based on the analysis PlanET propose any optimization and helps you to implement themEven in technical service, we are well positioned – from the feeding system to the CHP. Please have a look to the service flyer-.amino acidssugarslong-chain fatty acidsacetic acid hydrogen, CO2short-chain organic acids,alcohols, NH4, H2SmethanePage 35PlanET BiomethaneProduce Your Own Natural GasTreating biogas and feeding it into the natural gas grid considerably increases your degree of utilising the raw biogas, thus upgrading the overall efficiency of your biogas plant.• Biomethane is flexible: New sales possibilities in the heat and fuel market• Biomethane uses the existing infrastructure: Biomethane can be transported efficiently to the consumers via the natural gas grid• Biomethane stabilises the energy system: It compensates for fluctuating renewable energies (such as wind and solar power) by producing energy from biomethane as required That’s why feeding in biomethane, in addition to new construction projects, is also ideally suited for repowering projects or expanding existing biogas plants. In the process, a wide variety of business models make it possible to enter into value creation with organic natural gas. PlanET will provide you with independent consultation for selecting the right method, develop the business model that suits you best and bring strong project partners together. PlanET Biogastechnik GmbH has pursued the development steps in the field of biogas from the very outset and has thus succeeded in establishing a valuable and impartial information network of important contacts in the industry over the past few years.The Benefits at a Glance:• continuous observation and analysis of relevant developments in the industry• project-related, individual and site-specific concepts• impartial, independent information network• direct, personal contacts to technology leaders• everything from a single source – from planning all the way to implementation • plant tours upon request (national and international)Page 36Source: Deutsche Energie-Agentur GmbH (dena) http://www.biogaspartner.deSeveral different methods are available for refining biogas to natural gas quality (methane enrichment). The following table shows the individual methods and their mechanism of action.Method separation EffectPhysical washing, such as pressure water scrubbing, Genosorb washing, etc.Dissolution of CO2 in water or organic scrubbing solutionChemical scrubbing, i.e. with monoethanolamine (MEA scrubbing) Chemical reaction of CO2 with MEAPressure swing adsorption (PSA) Adsorption of CO2 with a carbon molecular sieveMembrane separation method Greater membrane permeability with CO2 than with CH4Low temperature separation (cryo-separation) Phase separation of liquid CO2 and gaseous CH4Page 37Technical data & InformationenPlanET Biogas Plant EfficiencyIn 2011, the Münster University of Applied Sciences evaluated 23 PlanET biogas plants in order to be able to make statements on the efficiency of existing PlanET plants in the performance range between 180 and 500 kW with a wide variety of substrate mixtures.Page 38PlanET Vario: 100 % Likelihood to Buy AgainA current survey conducted by the German open Business School in Ahaus made it clear: The modular expandable all-rounder received the top marks. The survey asked about fields of daily use, such as satisfaction in terms of the processing of the input materials, maintenance-friendliness and energy consumption. Over 88 percent responded to the question, “How satisfied are you with the Vario on the whole?” with “satisfied” or “very satisfied.” All respondents even said that would “probably” or “very probably” decide to by the PlanET Vario again.Number 1 in BiogasPlanET Biogastechnik scored the best overall results of all plant manufacturers in Germany’s largest biogas survey to date, conducted by the agricultural journal profi (starting with the 10/2008 issue). More than 9 of 10 of the operators asked said that they would buy their biogas plant from PlanET again. 2,580 operations in total were contacted for the survey in the spring of 2008. This is equivalent to about 70% of the biogas plants installed at that time. Based on an above-average return rate of 25% (631 questionnaires), the respondents surveyed provided the first representative data on the quality standards in German biogas plant construction. In addition to very good test results for PlanET in the fields of service and customer satisfaction, the total of 130,000 individual data items recorded also indicate above-average results for the categories agitator, fermenter, plant control, pump technology, processing and maintenance.The surveys of our customers are conducted on a regular and manufacturer-independent basis in order to steadily refine plant technology in a user-oriented manner. It’s not without reason that PlanET Biogastechnik’s quality is above average – what this ultimately means for our customers is durability, wear resistance and low internal power consumption.survey resultsPage 39PlanET Biogastechnik GmbHUp de Hacke 26 D-48691 VredenFon: +49 (0) 2564-3950-0Fax: +49 (0) 2564-3950-50www.planet-biogas.cominfo@planet-biogas.comFebruary 2013Errors and Modifications excepted. 130205 PlanET Produkte engl. final web_kl.pdf 130205 PlanET Produkte engl. final web_kl.pdf 130205 PlanET Produkte engl. final web_kl.pdf 130205 PlanET Produkte engl. final web.pdf