As engineers, we design and build solutions which are intended to bring expected results for our Customers. The best ideas come from nature. In order to achieve success, it is enough to translate them to the language of modern technologies and we are specialists in this field – we have long-term experience in manufacturing devices intended for demanding, frequently aggressive medium.
Agricultural biogas plants are the best way to produce ecological energy from renewable sources, without CO2 emission, regardless of weather and other factors, but with the application of substrates of plant and animal origin. Production of electric energy and heat in a typical biogas plant consists in subjecting substrates to natural anaerobic fermentation processes. Specially designed digesters provide ideal conditions for bacteria.
Processing substrates, such as corn silage or pig slurry, requires time, but mainly durable devices. All system elements – pumping stations, mixers, heating systems or membrane roof must be selected by the best technologists and executed in line with high production standards. This is the way we operate at Instalcompact.
Before organic matter present in substrates is transformed into biogas, it is stored in a digester for a relatively long time. Gas produced in this manner floats over the substrate level, where it is stored under the membrane roof dome, and then it is transformed by combined heat and power generation unit to electric and thermal energy. Only a small amount of produced energy is used for supplying biogas plant – approximately 75 % may be used for other purposes of agricultural farm, or even further resold !
Bacteria responsible for fermentation process have their needs and requirements, especially concerning the right load temperature and pH. Providing right conditions for them is the essence of biogas production. Well-executed heating of digesters provides continuous work of satisfied methane bacteria. Our experience in plastic forming of stainless steel allows us to manufacture reliable thermal systems for biogas plants.
Depending on the concept of the designer or technologist, substrate pumping stations may take various – less or more complicated shapes. Discharge of medium between two tanks can be performed by a simple pumping station, but it can also be a more complex system: pumping station transporting medium to all tanks and in all directions. Regardless of the level of design difficulty, we are able to find the best solutions. We have been creating pumping stations successfully for almost 20 years.
It is obvious that complex devices require precise control systems. Our long-term experience in creating software allows us to develop complex applications for managing biogas plants. System based on emsydia® controllers, devices of other manufacturers, or control cabinets manufactured by us, ensures comfortable operation of the entire biogas plant – the higher the level of process automation, the bigger the guarantee of process stability and working safety (minimisation of failure risk, monitoring of parameters, etc.)
A well-written algorithm delivered by the designers of the biogas plant optimises biogas plant operation, increases its efficiency and ensures proper functioning. It enables to create software thanks to which we can control the following parameters on an ongoing basis: