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WHIRLER CENTRIFUGALS PVT. LTD.
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Industrial-scale Waste Management Organic Waste CSTR (Continuous Stirred Tank Reactor) Thermophilic Biogas Plant

Industrial-scale Waste Management Organic Waste CSTR (Continuous Stirred Tank Reactor) Thermophilic Biogas Plant Specification

Frequency
50/60 Hz

Plastic Processed
N/A (Organic waste only)

Model No
Industrial CSTR-Thermophilic-2024

Usage & Applications
Organic waste management, dairy farms, agro-industries, municipal solid waste, effluent treatment

Production Capacity
Biogas production 70-85 m3/ton of feedstock; customized scale

Efficiency (%)
Biogas conversion efficiency: 70-80%

Automation Grade
Fully automatic/semiautomatic versions available

Driven Type
Electric-driven stirrer and pump

Temperature Range
50C to 57C (thermophilic operation)

Accessories
Feed mixing tanks, effluent storage tanks, gas scrubbing unit, online biogas meter, agitation system, heating coils, safety valves, gas storage dome

Installation Guideline
Professional installation by certified technician as per site layout; civil work required

Motor Power
5-30 HP (agitation and pump motors)

Speed
Variable - 20 to 100 RPM (agitator)

Type
Industrial-scale Waste Management Organic Waste CSTR (Continuous Stirred Tank Reactor) Thermophilic Biogas Plant

Material
High-grade stainless steel / mild steel with anti-corrosive coating

Computerized
Yes

Automatic Grade
Automatic

Control System
Programmable Logic Controller (PLC) with SCADA integration

Drive Type
Electric Motor (Agitator Drive)

Voltage
380 - 440V (Three Phase AC)

Power
Up to 50 kW (Depends on plant size and capacity)

Weight (kg)
Variable; typically 8000 to 50000 kg based on capacity

Dimension (L*W*H)
Customized based on requirement; typical scale: L: 15-30m, W: 8-20m, H: 7-14m

Color
Silver (steel) with protective paint finish

Capacity
10 to 1000+ m3/day

Features
Thermophilic digestion, high gas yield, automated feed and effluent systems, safety valves, online gas analyzers, heat recovery, PLC based operation, corrosion resistance, low maintenance

Machine Type
CSTR Biogas Plant

Surface Finish
Polished/painted corrosion-resistant surface

Power Consumption
8-50 kWh/day (depends on automation level and agitator size)

Safety Features
Pressure relief valves, PLC alarms, gas leak detection

Effluent Handling
Effluent discharge for use as liquid fertilizer

Monitoring
Online sensors for pH, temperature, pressure, and biogas composition

Operating Mode
Thermophilic

Heating System
Integrated heating coils for temperature maintenance

Digester Type
Anaerobic Continuous Stirred Tank Reactor (CSTR)

Compliance
Meets pollution control board and renewable energy agency standards

Water Requirement
Ratio of 1:1 water to feedstock (varies by process)

Civil Works Requirement
Anaerobic digester tank construction below/above ground as per layout

Feed System
Automated feed inlet with pre-mixing and slurry heating

Expansion Provision
Modular tank design for plant capacity upgradation

Biogas Utilization
Energy for thermal or electrical generation (CHP), direct firing, industrial use

Agitation Technology
Central shaft agitator with high-torque gearing

Gas Outlet System
Floating drum (inverted gasholder) with water seal

Feedstock Pre-treatment
Mechanical size reduction, slurry mixing

Gas Storage
Metallic or membrane gas holder

Retention Time
10-25 days (based on substrate quality and operating temperature)

Gas Purification
Multi-stage scrubbing unit (removal of H2S, CO2, particulates)

Application Examples
Dairy farms, piggeries, chicken litter, canteens, municipal organic waste

Operational Support
Remote monitoring and annual maintenance contract (AMC) option

Industrial-scale Waste Management Organic Waste CSTR (Continuous Stirred Tank Reactor) Thermophilic Biogas Plant Trade Information

Minimum Order Quantity
1 Number

Delivery Time
4

Industrial-scale Waste Management Organic Waste CSTR (Continuous Stirred Tank Reactor) Thermophilic Biogas Plant About

This industrial-scale waste management facility utilizes a Continuous Stirred Tank Reactor (CSTR) operating under thermophilic conditions (5060C) to process large volumes of organic waste. The CSTR design features active, continuous mechanical mixing, which ensures a highly homogeneous mixture, maximizes microbial contact with the organic substrate, and prevents solids from settling.

By operating in the higher thermophilic temperature range, the digestion process is significantly accelerated. This allows for faster biogas production, shorter hydraulic retention times, and superior pathogen destruction compared to standard mesophilic systems. Designed for heavy-duty municipal, agricultural, or industrial waste treatment, this high-performance facility effectively diverts organic waste from landfills. It converts raw organic materials into renewable biogas (methane) for clean electricity or heat generation, while producing a nutrient-rich digestate that serves as a premium biofertilizer, driving a sustainable circular economy.

Optimized Thermophilic Digestion for Maximum Biogas Output

By operating at elevated thermophilic temperatures, this CSTR biogas plant ensures rapid and efficient decomposition of organic waste, yielding 70-85 m3 biogas per ton of feedstock. The central shaft agitator, automated feeding, pre-mixing, and heating systems work in concert to maintain ideal microbial activity, fostering consistent gas production and process stability, even for high-volume municipal or agricultural operations.

Advanced Automation and Remote Monitoring Enhance Reliability

Fitted with a PLC-based control system complemented by SCADA integration, the plant features fully automated operation with real-time monitoring of key parameters (pH, temperature, pressure, biogas composition). The intelligent feed and discharge systems, coupled with remote diagnostic capabilities and annual maintenance contracts, deliver reduced downtime, improved process control, and support for large-scale industrial deployment.

Integrated Safety and Compliance for Peace of Mind

Comprehensive safety features such as pressure relief valves, alarms, and gas leak detection systems are embedded for operator security. The multi-stage scrubbing unit assures clean biogas by removing H2S, CO2, and particulates, while effluent handling enables the safe discharge or use of digestate as liquid fertilizer. Stringent adherence to pollution control and renewable energy norms ensures environmental compliance and social responsibility.

FAQ's of Industrial-scale Waste Management Organic Waste CSTR (Continuous Stirred Tank Reactor) Thermophilic Biogas Plant:

Q: How does the Continuous Stirred Tank Reactor (CSTR) technology work in this biogas plant?

A: The CSTR technology involves continuously stirring the digesting organic material inside a tank, ensuring even temperature and substrate mixing. This uniformity promotes optimal microbial activity and effective breakdown of feedstock, improving biogas yield while handling various organic waste types efficiently.

Q: What is the process for feeding organic waste into the system?

A: Organic waste undergoes pre-treatment, including mechanical size reduction and slurry mixing, before being automatically fed into the reactor. An integrated pre-mixing tank and automated inlet system ensure a consistent slurry, while heating coils maintain the desired thermophilic operating temperature for efficient digestion.

Q: When is the effluent generated by the plant suitable for use as fertilizer?

A: The effluent, a nutrient-rich digestate, is discharged continuously or as per the process cycle, typically after a retention time of 10-25 days. Once the digestion process is complete and the digestate is monitored for quality, it can be used directly as a liquid fertilizer, enhancing soil health.

Q: Where can this industrial-scale biogas plant be deployed?

A: The CSTR thermophilic biogas plant is suitable for dairy farms, piggeries, poultry operations, canteens, agro-industrial facilities, and sites managing municipal organic waste. The modular design allows flexible installation, whether above or below ground, depending on user layout and civil works planning.

Q: What are the main benefits of using an automated, thermophilic CSTR biogas plant?

A: Major benefits include high biogas conversion efficiency (70-80%), reduced organic waste disposal, production of renewable energy, generation of fertilizer, robust safety features, automated operation with minimal manual intervention, and scalability through modular expansion. Compliance with environmental and energy standards further enhances its value.

Q: How is gas purification and storage handled in this plant?

A: Biogas produced passes through a multi-stage scrubbing unit that removes hydrogen sulfide, carbon dioxide, and particulates, resulting in cleaner gas. The purified gas is then stored in either a metallic or membrane gasholder with a water-sealed floating drum, ready for use in power generation or industrial applications.

Q: What operational support is provided after installation?

A: Support services include professional installation by certified technicians, remote monitoring capabilities, and the option for an annual maintenance contract (AMC). Ongoing operational support ensures optimal performance, quick troubleshooting, and continued compliance with regulatory requirements.

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