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WHIRLER CENTRIFUGALS PVT. LTD.
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Industrial-scale Thermal Energy Animal Manure CSTR (Continuous Stirred Tank Reactor) High-Yield Bio-CNG Plant

Industrial-scale Thermal Energy Animal Manure CSTR (Continuous Stirred Tank Reactor) High-Yield Bio-CNG Plant Specification

Efficiency (%)
85-92%

Temperature Range
35-55C (mesophilic/thermophilic operation)

Driven Type
Electric motor coupled

Production Capacity
400-40,000 Nm3/day Biogas (or project specific)

Accessories
Gas collection dome, slurry outlet, gas outlet valve, pressure gauge, digestate storage tank, safety device, CHP engine (optional), dewatering equipment (optional)

Frequency
50-60 Hz

Speed
Variable (0-60 RPM) for stirrer/agitator

Installation Guideline
Civil foundation required; anchored reactor installation, trained technician mandatory

Motor Power
7.5-100 kW (agitation/feeding pumps)

Usage & Applications
Biogas/ Bio-CNG production, organic waste management, decentralized power generation, agricultural fertilizer

Model No
CSTR-IND-BIO-CNG (Customizable)

Automation Grade
Automatic

Type
Industrial-scale Thermal Energy Animal Manure CSTR (Continuous Stirred Tank Reactor) High-Yield Bio-CNG Plant

Material
Mild Steel/Concrete (per reactor design)

Computerized
Yes

Automatic Grade
Automatic

Control System
SCADA/PLC Based

Drive Type
Motor driven agitator

Voltage
415 V

Power
50-250 kW (Depending on plant capacity)

Weight (kg)
Custom - varies with capacity and design

Dimension (L*W*H)
Custom - varies with installation/per customer requirements

Color
Industrial Grey/Custom paint as per requirement

Capacity
2500-500000 liters or customer specific

Features
High-yield biogas/CNG production, co-digestion of organic waste and manure, integrated odor control, efficient mixing, robust construction

Surface Finish
Anti-corrosive paint/epoxy coated interior

Power Consumption
50-250 kW

Machine Type
CSTR Fixed Dome Digester

Mixing Mechanism
Top/side entry agitator with variable frequency drive

Biogas Application
Direct for cooking, heating, CHP, or upgraded to Bio-CNG for vehicles

Retention Time
20-40 days (process dependent)

Operating Mode
Continuous automated operation

Process Monitoring
Online pH, temperature, pressure, gas flow, and liquid level sensors

Gas Storage
Integrated Fixed Dome with membrane storage option

Feeding System
Automated substrate loading with solid/liquid dosing system

Designed Life
15-20 years with proper maintenance

Output Digestate Type
Separated into liquid and solid fraction for agricultural use and composting

Safety Devices
Flame arrestor, water seal, back-pressure relief valve

Project Compliance
Complies with national biogas and renewable energy guidelines

Site Requirement
Electric supply, water connection, civil structure, waste feeding provision

Anaerobic Digestion Phase
Single-phase CSTR

Gas Purification
H2S scrubber, Moisture Trap, CO2 removal unit (if CNG upgrade is required)

Corrosion Protection
Epoxy-lined interior/anti-corrosive paint

Industrial-scale Thermal Energy Animal Manure CSTR (Continuous Stirred Tank Reactor) High-Yield Bio-CNG Plant Trade Information

Minimum Order Quantity
1 Number

Delivery Time
4

Industrial-scale Thermal Energy Animal Manure CSTR (Continuous Stirred Tank Reactor) High-Yield Bio-CNG Plant About

This state-of-the-art, industrial-scale biogas facility utilizes a **Continuous Stirred Tank Reactor (CSTR)** to process animal manure into high-yield **Bio-CNG** and clean thermal energy. Designed for large-scale agricultural and waste management operations, the CSTR technology ensures continuous mixing and optimal temperature control, maximizing anaerobic digestion efficiency and biogas production.

The raw biogas is upgraded to biomethane and compressed into Bio-CNG, serving as a renewable, carbon-neutral fuel for transportation and industrial use. Simultaneously, the system captures thermal energy, which is recycled to maintain digester temperatures and supply heat to local processes.

By converting livestock manure into high-value fuel and thermal energy, this plant significantly reduces greenhouse gas emissions, manages agricultural waste responsibly, and generates a nutrient-rich organic digestate for fertilizer, embodying a highly efficient circular economy solution.

***

Advanced Automated Feeding and Mixing

The plant's automated substrate loading system efficiently manages solid and liquid waste input, minimizing labor and optimizing feedstock usage. Top or side-entry agitators, controlled by a variable frequency drive, ensure homogenous mixing and maximize contact between microorganisms and organic matter. This automated approach enhances productivity while reducing maintenance needs.

Cutting-Edge Gas Storage and Purification

Biogas is safely collected in an integrated fixed dome or optional membrane storage, then directed through advanced purification processes. Key systems remove H2S, moisture, and CO2 (for CNG upgrade), ensuring safe and high-quality output suitable for direct combustion or vehicle-grade fuel. Gas monitoring and safety devices provide operational security and efficiency.

Robust Design and Long Service Life

Constructed from epoxy-lined mild steel or concrete, the reactor resists corrosion and ensures extended durability. The plant's design life of 15-20 years, combined with automated control and SCADA/PLC-based monitoring, offers dependable operation. Customizable size and power options allow adaptation to diverse site requirements and customer needs.

FAQ's of Industrial-scale Thermal Energy Animal Manure CSTR (Continuous Stirred Tank Reactor) High-Yield Bio-CNG Plant:

Q: How does the automated feeding system work in this bio-CNG plant?

A: The automated feeding system utilizes both solid and liquid dosing units to continuously load organic substrates and animal manure into the reactor. This system is designed for efficient, uninterrupted feeding, reducing manual handling and optimizing the anaerobic digestion process to maximize biogas production.

Q: What kind of waste can be processed with this CSTR bio-CNG plant?

A: The plant is engineered to co-digest various organic wastes, primarily animal manure and agricultural residues, but it can also handle other biodegradable materials. The robust mixing mechanism ensures efficient processing of both liquid and solid substrates for maximum gas yield.

Q: When should the digestate be removed, and how is it managed?

A: Digestate is separated online into solid and liquid fractions. Removal timing depends on retention time-typically 20 to 40 days based on process conditions. The solid digestate is suitable for composting, while the liquid fraction can be used as nutrient-rich fertilizer in agriculture.

Q: Where can the produced biogas or Bio-CNG be used?

A: The high-purity biogas or upgraded Bio-CNG can be utilized directly for cooking, heating, and combined heat and power (CHP) production at the plant site. Alternatively, upgraded Bio-CNG is suitable for vehicular fuel, enabling decentralized power generation and sustainable transportation.

Q: What are the main benfits of adopting this industrial-scale CSTR bio-CNG plant?

A: Key benefits include high biogas/CNG output, automated operation with reduced labor, co-digestion of diverse wastes, integrated odor control, online monitoring, compliance with renewable energy standards, and valuable digestate by-products for agriculture. The robust, corrosion-resistant design ensures long-term, efficient operation.

Q: How is process safety ensured in the reactor system?

A: Multiple safety features safeguard plant operation, including flame arrestors, water seals, back-pressure relief valves, and online monitoring for pH, temperature, gas flow, and pressures. These systems work in tandem to prevent accidents and maintain stable anaerobic digestion conditions.

Q: What site requirements are necessary for installing the plant?

A: A suitable location should provide electric power (415 V), water connection, civil foundation for reactor anchoring, and accessible waste feedstock provision. Installation and commissioning must be handled by trained technicians as per supplied guidelines to ensure safe, compliant, and optimal plant performance.

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