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WHIRLER CENTRIFUGALS PVT. LTD.
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Commissioning Grid Injection Dairy Manure Covered Lagoon Co-Digestion Biogas Plant

Commissioning Grid Injection Dairy Manure Covered Lagoon Co-Digestion Biogas Plant Specification

Frequency
50/60 Hz

Installation Guideline
Requires Civil Works for Digester, HDPE Anti-leakage Liner, Electrical and Pipe Connections

Model No
DML-FD-GL500 (example/reference)

Accessories
Biogas Flowmeters, Pressure Gauges, Gas Valves, Water Traps, Digester Agitators, Digestate Pumps, Gas Filters, Safety Valves

Production Capacity
Up to 350-700 m3/day biogas (input and scale dependent)

Automation Grade
Fully Automatic

Motor Power
5-10 HP (for stirrer and pumping, varies by scale)

Driven Type
Electrical with Mechanical Supports

Efficiency (%)
Biogas Yield Efficiency: 65-70% (organic matter to biogas conversion)

Speed
Varies as per mixer/agitator specification (20-60 RPM)

Usage & Applications
Biogas Production for Power Generation, Cooking, Fertilizer Production, Grid Injection

Temperature Range
Ambient (Mesophilic : 30C-38C), with thermal enhancement options

Type
Grid Injection Dairy Manure Covered Lagoon Co-Digestion Biogas Plant

Material
Reinforced Concrete, Biogas-safe sealing membrane, Stainless Steel Piping

Computerized
Yes

Automatic Grade
Automatic

Control System
PLC Based Automated Control

Drive Type
Electric Motor and Mechanical Stirrer

Voltage
380-480V (Three Phase)

Power
Customizable from 50 kW to 500 kW

Weight (kg)
Varies by Plant Size (~15,000 - 60,000 kg)

Dimension (L*W*H)
Custom (Example: 20m x 10m x 4m for 500 m3 digester)

Color
Grey/Green (customizable with corrosion protection finish)

Capacity
Up to 50,000 m3 biogas/year (site dependent)

Features
Co-digestion of dairy manure and food waste, Covered Lagoon for odor control, Fixed Dome Digester, Grid Injection Ready, Digestate Outlet, Gas Storage Dome, Biogas Collection and Metering, Fertilizer Output, Automated Operation, Safety Pressure Gauges

Power Consumption
20-40 kWh/day (operations, stirrers, controls)

Machine Type
Industrial Biogas Plant (Fixed Dome Type)

Surface Finish
Epoxy or Polymer-based anti-corrosive coating

Biogas Utilization
Combined Heat & Power (CHP), Biogas Upgrading for Grid, Cooking Fuel

Odor Control
Complete Lagoon Cover and Gas Tight System

Carbon Emission Reduction
Approx. 2.3 tons CO2e/tonne feedstock treated per year

Backup System
Diesel/Electric Generator for Power Backup

Compliance
Meets Local Grid Injection Biogas Standards

Safety Systems
Gas Pressure Relief Valve, Flame Arrestor, Gas Leak Detector

Design Life
20+ Years (Typical With Maintenance)

Feedstock Flexibility
Suitable for Manure, Food Waste, Green Waste, Slurries

Operator Requirement
1-2 Trained Personnel per Shift

Commissioning Time
3 to 6 Months from Start-to-Finish

Outlet Gas Purity
~55-65% Methane by Volume

Digestate Output
Liquid and solid fertilizer, compostable material

Remote Monitoring
SCADA/IoT Enabled (Optional)

Slurry Handling
Automatic Slurry Feeding and Discharge

Commissioning Grid Injection Dairy Manure Covered Lagoon Co-Digestion Biogas Plant Trade Information

Minimum Order Quantity
1 Number

Delivery Time
4

Commissioning Grid Injection Dairy Manure Covered Lagoon Co-Digestion Biogas Plant About

This state-of-the-art biogas plant, currently undergoing its final commissioning phase, utilizes an advanced covered lagoon anaerobic digestion system designed primarily for processing liquid dairy manure. By incorporating co-digestion technology, the facility processes agricultural dairy waste alongside organic co-substrates, which significantly increases biogas yields and optimizes local waste management. The captured biogas is upgraded on-site to pipeline-quality biomethane for direct grid injection, providing a clean, renewable alternative to fossil fuels that seamlessly integrates into the regional gas distribution network. Representing a highly efficient circular economy model at the intersection of agriculture and green technology, the project delivers major environmental benefits. It mitigates greenhouse gas emissions from livestock manure and diverts organic waste from landfills, while generating a nutrient-rich organic digestate that local farmers can use as sustainable fertilizer, all while injecting green energy directly into the utility grid. Ultimately, this facility exemplifies the future of sustainable farming and renewable energy production.

Versatile Waste-to-Energy Solution

Our biogas plant is designed to handle a range of organic feedstocks, including dairy manure, food waste, and green waste. The co-digestion process enhances biogas yield and allows flexibility according to available resources on site. The fully covered lagoon technology virtually eliminates odor and provides a robust, reliable system for sustainable operation.

Automated Operation & Advanced Safety Measures

The plant uses state-of-the-art PLC-based automation for slurry feeding, discharge, and biogas controls, reducing manual intervention. Integrated safety features-such as pressure relief valves, flame arrestors, gas leak detectors, and power backup-prioritize operational safety and reliability even under demanding conditions.

Sustainable Output and Environmental Benefits

Designed to meet local biogas grid injection standards, the facility substantially reduces carbon emissions, with a typical reduction of approximately 2.3 tons CO2e per tonne of feedstock processed. By converting organic waste to energy and valuable digestate for fertilizer, the plant supports circular agriculture and sustainable energy production.

FAQ's of Commissioning Grid Injection Dairy Manure Covered Lagoon Co-Digestion Biogas Plant:

Q: How long does it take to commission the Dairy Manure Covered Lagoon Co-Digestion Biogas Plant?

A: The commissioning process for the plant typically requires 3 to 6 months from start to finish, which includes site preparation, installation, civil works, and testing phases to ensure compliance with safety and efficiency standards.

Q: What safety systems are implemented in the plant and how do they work?

A: The plant integrates several safety mechanisms such as gas pressure relief valves, flame arrestors, and gas leak detectors. These systems continuously monitor and manage gas pressure, prevent flame transmission, and quickly alert operators to any gas leaks, ensuring safe operation at all times.

Q: What types of feedstock can the plant process and what are the benefits?

A: The system is designed for flexibility and can process dairy manure, food waste, green waste, and slurries. This co-digestion approach improves biogas yield, offers waste management solutions, and provides nutrient-rich digestate useful as high-quality fertilizer.

Q: How is odor controlled during operation?

A: Odor control is accomplished using a complete lagoon cover and a gas-tight system, which prevent odor emissions and capture biogas efficiently. This design ensures a minimal environmental footpint and enhances site acceptability.

Q: What is the outlet gas purity and typical biogas usage?

A: The product outlet gas typically contains 55-65% methane by volume, making it suitable for Combined Heat & Power (CHP) applications, direct grid injection after upgrading, and as clean cooking fuel. Biogas can also be stored or metered as needed.

Q: How many personnel are required for plant operation and is remote monitoring available?

A: Only 1 to 2 trained personnel per shift are required due to high automation levels. Optional SCADA/IoT remote monitoring allows operators to supervise and control plant processes from a distance, increasing efficiency and response times.

Q: What are the environmental advantages of this biogas plant?

A: By treating organic waste, the plant achieves an estimated reduction of approximately 2.3 tons of CO2 equivalent per tonne of feedstock each year, helping clients comply with carbon reduction targets and promoting sustainable, circular resource management.

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