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WHIRLER CENTRIFUGALS PVT. LTD.
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Commercial Electricity Generation Agricultural Residue CSTR (Continuous Stirred Tank Reactor) Continuous Bio-CNG Plant

Commercial Electricity Generation Agricultural Residue CSTR (Continuous Stirred Tank Reactor) Continuous Bio-CNG Plant Specification

Model No
Based on Capacity & Requirement

Driven Type
Electric motor driven with gearbox

Motor Power
15-75 HP (Based on agitator & pump size)

Accessories
Feed pumps, gas booster, control panel, gas storage, fire & explosion mitigation systems

Efficiency (%)
Up to 90% substrate conversion efficiency

Installation Guideline
Civil foundation required; commissioning by trained engineers; provision for feed and digestate handling required

Speed
rpm as per agitation process (typically 20-40 rpm)

Automation Grade
Fully Automatic

Usage & Applications
Commercial electricity generation, vehicle fuel (Bio-CNG), replacement for LPG/PNG, organic fertilizer production

Frequency
50/60 Hz

Production Capacity
Up to 1000 Nm3 Bio-CNG/day (per module)

Temperature Range
Mesophilic (35-42C) or Thermophilic (50-55C) Configurations Available

Type
Continuous Stirred Tank Reactor (CSTR) Continuous Bio-CNG Plant

Material
Mild Steel / RCC / Stainless Steel (based on design)

Computerized
Yes

Automatic Grade
Automatic

Control System
PLC Based Automated Control System

Drive Type
Motor Driven (AC Electric motor)

Voltage
380-440 V

Power
Varies with plant capacity (typical range: 20 kW - 250 kW)

Weight (kg)
Varies by model (e.g., 12,000 - 32,000 kg)

Dimension (L*W*H)
Customized per site; e.g., 12m x 6m x 5m

Color
As per client requirement (Standard: Green/Grey)

Capacity
From 1 Ton/day up to 300 Tons/day (larger on request)

Features
Continuous operation, high biogas yield, sludge management, odor free, remote monitoring, modular design, energy efficient.

Power Consumption
Optimized ~0.2 to 0.4 kWh/kg processed

Machine Type
Fully Automatic Biogas/Bio-CNG Plant

Surface Finish
Corrosion Resistant Coating

Substrate Flexibility
Handles variety of agricultural & food waste substrates, cattle manure etc.

Support Service
Installation, AMC, technical training provided

Expansion Capability
Modular design for scale-up

Output Applications
Cooking, power generation, vehicle fuel, fertilizer industry

Safety Features
Flame arrestors, pressure relief valves, gas leak sensors, automated shutdown

Digestate Handling
Automated solids-liquid separation, digestate tank, liquid fertilizer outlet, compost outlet

Operator Manpower
Low; remote operation possible

Feedstock Input System
Automatic, with substrate preprocessing, chopping and mixing

Biogas Purification
PSA/Wheel/Water Scrubbing with H2S, CO2 & moisture removal, upgradable to Bio-CNG

Environmental Compliance
Zero liquid discharge possible, odor free, reduced GHG emissions

Biogas Collection System
Integrated dome/cap gas holder, high/low pressure lines, water trap, gas booster pump

Retention Time
Typically 35-40 days (for agricultural residue at mesophilic range)

CHP Integration
Built-in for electricity generation (optional: generator/CHP module)

Scada/Remote Monitoring
Web/network enabled monitoring panel, alarms, data logging

Commercial Electricity Generation Agricultural Residue CSTR (Continuous Stirred Tank Reactor) Continuous Bio-CNG Plant Trade Information

Minimum Order Quantity
1 Number

Delivery Time
4

About Commercial Electricity Generation Agricultural Residue CSTR (Continuous Stirred Tank Reactor) Continuous Bio-CNG Plant

This state-of-the-art commercial facility utilizes agricultural residues, such as crop waste and manure, as sustainable feedstock for clean energy production. Operating on a Continuous Stirred Tank Reactor (CSTR) system, the plant ensures a continuous, highly efficient anaerobic digestion process. This continuous feeding mechanism, combined with constant mechanical stirring, optimizes microbial activity and maximizes biogas yield.

The raw biogas is processed through two high-value pathways. First, a portion is converted into electricity for commercial grid injection or local industrial use, supporting clean power generation. Second, the remaining biogas undergoes advanced purification to produce Bio-CNG (compressed biomethane), a green, high-purity alternative fuel for transport and industrial applications.

By combining CSTR technology with dual energy outputs, this plant offers a circular economy solution that mitigates agricultural waste, reduces greenhouse gas emissions, and delivers reliable, renewable energy on a commercial scale.

Efficient Waste-to-Energy Conversion

This plant excels in converting diverse agricultural and food waste substrates into biogas and Bio-CNG through an advanced Continuous Stirred Tank Reactor (CSTR) process. With preprocessing and mixing, it achieves up to 90% substrate conversion efficiency, supporting continuous, high-yield operation and significantly reducing waste management challenges for commercial enterprises.

Automated Control and Remote Monitoring

Equipped with a PLC-based automated control system and SCADA-enabled remote monitoring, the plant allows real-time performance tracking, alarms, and data logging. Low on-site manpower needs and robust automation maximize operational convenience and reliability, letting operators manage the plant from anywhere with network access.

Integrated Safety and Environmental Compliance

Safety is at the forefront, with flame arrestors, pressure relief, gas leak detection, and automated shutdown features built in. The design supports zero liquid discharge, minimized odor, and a reduced greenhouse gas footprint, ensuring the plant meets rigorous environmental & industrial standards while enabling clean energy generation.

FAQ's of Commercial Electricity Generation Agricultural Residue CSTR (Continuous Stirred Tank Reactor) Continuous Bio-CNG Plant:

Q: How does the CSTR Bio-CNG plant process various substrates into energy?

A: The plant uses a Continuous Stirred Tank Reactor (CSTR) system, which employs automated feedstock preprocessing-including chopping and mixing-to efficiently digest agricultural residues, food waste, and manure. The reactor operates under mesophilic or thermophilic conditions, converting substrates into biogas. Purification systems then refine the gas to Bio-CNG quality, which can be used for electricity, fuel, or heat.

Q: What are the main benefits of using a fully automatic Bio-CNG plant for commercial applications?

A: A fully automatic Bio-CNG plant ensures high biogas yield, continuous operation, and up to 90% substrate conversion efficiency. Automated feed and digestate handling, remote monitoring, and integrated safety features significantly reduce operator work and improve plant reliability. Its modular design allows easy expansion based on the increasing waste generation or energy needs.

Q: When is the typical retention time for agricultural residue in this plant?

A: The typical retention time for processing agricultural residues in the CSTR is 35-40 days under mesophilic conditions (35-42C), ensuring thorough bioconversion and optimal gas yield.

Q: Where can the generated Bio-CNG and digestate outputs be utilized?

A: Produced Bio-CNG can be used for commercial electricity generation, as vehicle fuel, or as a replacement for LPG/PNG. The plant's digestate outputs-liquid fertilizer and compost-are valuable for agriculture, horticulture, and organic farming industries.

Q: What are the key safety features included in the plant design?

A: Safety is ensured through flame arrestors, pressure relief valves, gas leak sensors, an automated shutdown system, and fire/explosion mitigation accessories. These features are integrated into both the gas collection and overall plant control framework, minimizing operational risks.

Q: How is the plant operated and what support services are provided?

A: The plant runs on a PLC-based, fully automated system with remote monitoring and control via a network-enabled panel. Minimal operator manpower is needed. Installation, annual maintenance contracts (AMC), and technical training are provided for smooth commissioning and ongoing operation.

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