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WHIRLER CENTRIFUGALS PVT. LTD.
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Industrial-scale Grid Injection Animal Manure Dry Digestion Scrubber-Integrated Anaerobic Digester Plant

Industrial-scale Grid Injection Animal Manure Dry Digestion Scrubber-Integrated Anaerobic Digester Plant Specification

Production Capacity
Biogas output from 1000 Nm3/day to 25000 Nm3/day (scalable)

Driven Type
Electrically driven systems for agitator, feed and effluent pumps

Installation Guideline
On-site installation by certified engineers, includes commissioning and operator training

Frequency
50/60 Hz

Model No
DSGADIS-2024

Efficiency (%)
Biogas yield efficiency: 75-85% (feedstock conversion rate)

Usage & Applications
Biogas production from dairy manure, agricultural residues, and organic waste; grid injection; organic fertilizer production

Plastic Processed
N/A - plant is for organic material

Automation Grade
Fully Automatic

Speed
Agitator Speed: 20-60 rpm (variable)

Temperature Range
35-55C (mesophilic or thermophilic operation possible)

Accessories
Gas scrubbing unit, heat exchanger coils, effluent fertilizer output, water seal drum, online control panel, safety valves, pressure relief

Motor Power
Agitator motor: 7.5-15 kW (per unit); Pump motor: 5.5-11 kW (per unit)

Type
Industrial-scale Grid Injection Animal Manure Dry Digestion Scrubber-Integrated Anaerobic Digester Plant

Material
High-grade stainless steel with anti-corrosive treatment and specialist polymers for sealing

Computerized
Yes

Automatic Grade
Fully Automatic

Control System
Programmable Logic Controller (PLC) with SCADA Remote Monitoring

Drive Type
Electric motor-driven agitators and pumps

Voltage
380-480V, 3-phase, 50/60 Hz

Power
80-200 kW (scalable model dependent)

Weight (kg)
From 18000 kg (model dependent)

Dimension (L*W*H)
Bespoke plant design - Example: 18m x 8m x 8m (customizable as per capacity)

Color
Industrial Grey, Custom RAL available

Capacity
60 m3 to 3000 m3 per day (feedstock dependent)

Features
Integrated gas scrubbing & scrubbing unit, automated feed and effluent removal, automated agitator, online remote monitoring, high-yield biogas drum design, heat recovery system, effluent line for fertilizer

Power Consumption
Approx. 10-20% of energy produced used for plant operation

Surface Finish
Galvanized/industrial paint with anti-corrosive coating

Machine Type
Continuous Dry Anaerobic Digestion Biogas Plant

Commissioning Time
6-10 weeks from site clearance to operational handover

Thermal Management
High-efficiency heating coils for stable digestion temperature

Upgrade Options
Optional gas compression, bottling solutions, and grid injection modules

Material Ingress/Egress
Feed hopper for slurry; automated discharge for digestate

Compliance
Meets EU/ISO/Indian biogas plant and emission standards

Maintenance Cycle
Primary service every 12 months; daily self-cleaning routines

Feedstock Flexibility
Handles thick and dry cattle/dairy manure, straw, and mixed organic wastes

SCADA Connectivity
Remote real-time monitoring and control with alarm diagnostics and reporting

Mixing Technology
Central shaft paddle agitator for optimal substrate homogenization

Construction Standard
Factory-built modular sections for fast site installation; seismic-rated structural design

Plant Lifespan
20-25 years (with regular maintenance)

Overflow & Safety
Multiple precision-level sensors, automated overflow prevention

Effluent Treatment
Anaerobic digestate outflow for direct fertilizer use or further post-treatment

Environmental Impact
Reduces GHG emissions, odor control at source, recycles organic waste into clean energy

Gas Production Start Time
Biogas production begins within 24-72 hours of initial startup (dependent on substrate)

Storage System
Integrated high-pressure steel gas storage cylinders/tanks

Gas Outlet Pipe Specification
Corrosion-proof, 304/316 stainless steel, 100-220mm dia (based on output)

Output Gas Quality
Methane concentration 55-65% raw, 97%+ after scrubbing

Biogas Purification
Advanced scrubbing unit removes H2S, water vapor, and particulates for grid-grade methane (>97%)

Industrial-scale Grid Injection Animal Manure Dry Digestion Scrubber-Integrated Anaerobic Digester Plant Trade Information

Minimum Order Quantity
1 Number

Delivery Time
4

About Industrial-scale Grid Injection Animal Manure Dry Digestion Scrubber-Integrated Anaerobic Digester Plant

This industrial-scale anaerobic digester plant is a state-of-the-art waste-to-energy facility designed to process large volumes of animal manure using high-solids dry digestion technology. Unlike traditional wet digestion, dry digestion efficiently processes stackable organic materials with high dry-matter content, requiring minimal water addition and yielding optimal biogas output.

The facility is equipped with an integrated gas scrubber system that purifies raw biogas by removing impurities like carbon dioxide ($text{CO}_2$) and hydrogen sulfide ($text{H}_2text{S}$). This upgrading process transforms the raw gas into pipeline-quality, high-purity biomethane.

By integrating directly with local energy distribution infrastructure, the plant injects this clean biomethane directly into the natural gas grid. This advanced circular economy solution drastically reduces agricultural greenhouse gas emissions, offers farm operators a sustainable waste management solution, and delivers a reliable stream of renewable natural gas directly to energy consumers.

Seamless Feedstock Flexibility and High Yield

Engineered to digest a diverse range of thick and dry organic materials-including cattle/dairy manure, straw, and mixed organic waste-the plant maintains high yield biogas production. Its powerful paddle agitator ensures thorough mixing, maximizing the efficiency of anaerobic digestion and feedstock conversion rates of up to 85%.

Advanced Biogas Purification System

The integrated scrubbing unit delivers exceptional biogas purification, extracting hydrogen sulfide, water vapor, and particulates to produce methane at concentrations exceeding 97%. This process readies the biogas for direct grid injection, ensuring compliance with rigorous EU, ISO, and Indian standards as well as sustainable energy initiatives.

Automated Operation and Safety Features

A Programmable Logic Controller (PLC) with SCADA connectivity enables remote, real-time monitoring, alarm diagnostics, and comprehensive process control. Multiple precision-level sensors, automated discharge systems, and robust overflow prevention mechanisms provide optimal safety and plant uptime, supporting service cycles of up to 12 months.

FAQ's of Industrial-scale Grid Injection Animal Manure Dry Digestion Scrubber-Integrated Anaerobic Digester Plant:

Q: How does the anaerobic digestion process work in this plant?

A: The plant utilizes a continuous dry anaerobic digestion method where organic feedstocks like cattle manure, straw, and mixed wastes are homogenized by a central shaft paddle agitator. Microbial activity in a controlled, oxygen-free environment breaks down the material, producing raw biogas and digestate. The advanced scrubbing unit then purifies the biogas to over 97% methane, suitable for grid injection.

Q: What types of waste can the plant process effectively?

A: This facility is designed to treat thick and dry organic substrates, including cattle and dairy manure, straw, and other mixed agricultural or organic wastes. Its robust mixing and feeding systems allow for versatile input ranges, maintaining steady, high-efficiency performance across diverse waste streams.

Q: What is the typical timeline for gas production and commissioning?

A: Biogas production typically begins within 24 to 72 hours after the initial startup, depending on feedstock composition. From site clearance to operational handover, the plant can be fully commissioned and operational within 6 to 10 weeks.

Q: How is the output gas quality ensured for grid injection?

A: The plant's integrated scrubbing system removes hydrogen sulfide, water vapor, and particulates from the raw biogas, raising methane concentration from 55-65% in raw form to over 97%. This purification process ensures the output meets stringent grid injection and environmental standards.

Q: Where is the plant constructed and how is it installed on-site?

A: Each plant is factory-built in modular sections using high-grade stainless steel and specialist polymers. Installation is performed on-site by certified engineers, with commissioning, operator training, and safety checks as part of the service, ensuring rapid deployment and compliance with seismic standards.

Q: What are the operational and environmental benefits of using this plant?

A: The plant significantly reduces greenhouse gas emissions and odor by efficiently converting organic waste into clean biogas and organic fertilizer. With features like energy recovery, automated operation, and minimal odor, it supports environmental sustainability and boosts farm and industrial circularity.

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