BEKON Mini - Dry Fermentation Biogas Plant
The superiority of BEKON technology is already apparent from the wide diversity of suitable substrates. Bulk materials with a high dry-substance content can be digested without need for any complex pre-treatment of the fermentation material. The principle is quite simple: in the absence of air and following inoculation by previously fermented material, the biological waste begins to digest, immediately resulting in the production of biogas.
Product Details
The BEKON process is a single-step fermentation process that employs batch operation. ’Single step‘, in this sense means that the various degradation reactions (hydrolysis, acidification and methanisation) constitute one process step.
Filling the digesters using batch operation
The organic waste is collected in a tipping building and taken to the garage-shaped fermenter by wheel loader. Inoculation takes place by mixing the fresh material with material that already has been in a fermenter. Once it has been filled, the fermenter is closed off by a hydraulic hatch and the process of organic waste fermentation initiated. Excess cell fluid (percolation liquid) discharged during the fermentation process is collected by a drainage system and returned to the fermenting material in a cycle to keep it moist. Wall and floor heating is used to keep the temperature of the microorganisms constant. In this way, the conditions in the fermenter are maintained at an optimum level for the bacteria used in biogas production. This requires neither further mixing of the materials nor the addition of further material.
Continuous generation of electricity and heat
The biogas thus produced is generally utilised in combined heat and power (CHP) units for generating electricity and heat. Continuous operation of the CHP is ensured by filling and operating several fermenters at staggered time intervals. The electricity generated is fed into the electrical grid and is remunerated or sold on, subject to the national feed-in tariffs.
Only a small proportion of the excess heat produced is required for operating the plant. The majority of the heat energy generated is utilised externally; for example, it may be fed into a local or district heating grid or used for drying materials.
Generation of biomethane
Alternatively to power generation, the produced biogas can be processed into biomethane. This can then be fed into the natural gas grid or used as vehicle fuel (compressed natural gas). Thereby the generated energy can be stored and used in a wider market.
Sustainable Cycle for the Future
Digestate turned into quality compost
Once the fermentation process is finished, each fermenter is fully emptied by a wheel loader. The BEKON process generates a dry fermentation residue which means that it is not necessary to separate or press the digestate allowing further compost processing. Part of the material is used for inoculating new biomass and is returned to the cycle. BEKON has developed an enclosed tunnel composting process for treating the dry fermentation residue. The exhaust air emitted by tunnel composting is cleaned using a biofilter, thus avoiding the emission of odours. The final composting stage generally takes the form of windrow composting. The final compost is a valuable organic quality fertiliser used in agriculture and gardening, possibly generating additional revenue.
Innovation – thermophilic dry fermentation
The BEKON process can be operated at both mesophilic (37 – 40°C) and thermophilic (50 – 55°C) temperatures.
The thermophilic treatment (50 – 55°C) of biological waste ensures that it is safely sanitized in accordance with the biowaste ordinance. The BEKON process complies with the Animal By-product Regulation (ABPR), the German BioAbfV and the Swiss VTNP.
This hygienisation process in the fermenter is not affected by weather influences and there is no need for the standard and time-consuming monitoring of the post-composting phase. The thermophilic microorganisms are characterised by a high metabolism which leads to a biogas yield up to 20 % higher than other technologies. The fast thermophilic process enables a reduction of the retention time in the fermenter, leading to a higher throughput for each fermenter. BEKON´s first thermophilic plant has been operating successfully in Thun (Switzerland) since the end of 2010. This was followed in December 2013 by a second thermophilic plant in Steinfurt (Germany) with an annual capacity of 45,000 tons of source separated waste.
Types of organic waste that can be processed using the BEKON technology
- source separated waste
- green waste
- organic fraction of municipal solid waste
- other organic waste materials
- The BEKON process is also suitable for all types of bulk or stackable biomass without any preliminary treatment being required.
Advantages
Wide range of suitable organic waste materials
Besides municipal source separated wastes, other organic wastes with a high dry-substance content can be processed for energy production. Contaminants only have a minor effect on the BEKON process. The robust wheel loader operation enables also the use of difficult input materials.
Modular construction, easy maintenance
Fermenters are constructed as water retaining concrete structures and are technically gas-tight. The wall and floor heating system (patented) is integrated into the concrete wall and floor sections during plant construction in order to optimise the organic degradation processes in the fermenter. The plant’s modular construction consisting of several fermenters allows for expansion if desired to increase the plant capacity.
Maintenance costs for the overall plant are very low. Thanks to its patented process, BEKON does not need to use any stirring equipment in the fermenter. The hydraulic hatch of the fermenter is opened upwards to ensure that the integrated inflatable sealing cannot be inadvertently damaged while the wheel loader is loading or unloading. BEKON plants are regarded as extremely reliable in their operation because of the robust technology and sophisticated construction. BEKON’s technological leadership is established by these factors.
Simple, robust technology with low operating costs
BEKON provides proven and reliable technology which can be ideally employed alongside existing composting facilities. The existing infrastructure with wheel loaders can be used ideally. No pumps or mixers are necessary for operation. The material for fermentation generally requires no pre-treatment. For these reasons the machine and personnel operation costs are less expensive compared to the wet fermentation process.
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