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WHIRLER CENTRIFUGALS PVT. LTD.
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Operational Grid Injection Agricultural Residue Dry Digestion Co-Digestion Anaerobic Digester Plant

Operational Grid Injection Agricultural Residue Dry Digestion Co-Digestion Anaerobic Digester Plant Specification

Frequency
50 Hz

Automation Grade
Automatic

Speed
Mixer operation: 20-60 RPM

Plastic Processed
N/A (Application is for organic biomass)

Driven Type
Electric Motor/PLC System

Efficiency (%)
80-92%

Usage & Applications
Biogas production from agricultural residue, food & animal waste; fertilizer/digestate output; power & heat generation for grid supply

Motor Power
2-30 HP (depends on mixer/feeder specification)

Temperature Range
Mesophilic (30-40C), Thermophilic (50-60C)

Production Capacity
Biogas production up to 25,000 m3/month (site dependent)

Accessories
Pressure gauge, flow meter, water trap, gas outlet valve, biogas storage, CHP module, manure/biomass feeder, removable dome cover, outlet piping

Installation Guideline
On-site installation by qualified engineering team, foundation prep required

Model No
Custom/Project Specific

Type
Operational Grid Injection Agricultural Residue Dry Digestion Co-Digestion Anaerobic Digester Plant

Material
Reinforced concrete, Steel (for dome, pipes, and structural parts)

Computerized
Yes (with automated control and data logging system)

Automatic Grade
Automatic

Control System
PLC based control panel

Drive Type
Electric Motor Driven Pumps & Mixers

Voltage
380-415V (Three Phase)

Power
Customizable, typically 5-50 kW depending on size/capacity

Weight (kg)
Varies by plant size (typical digester >15000 kg)

Dimension (L*W*H)
Custom-built as per site and capacity, example: 20m x 10m x 8m

Color
Industrial Grey/Green (customizable)

Capacity
5-500 m3/day (based on input/agricultural residue availability)

Features
Dry digestion, co-digestion capability, grid-injection ready, high-yield biogas generation, robust digester, pressure gauge, water trap, removable cover, fertilizer output

Machine Type
Fixed Dome Anaerobic Digester

Surface Finish
Anti-corrosive epoxy paint/galvanized

Power Consumption
Variable, based on plant capacity

Gas Utilization Options
Direct biogas to gas stove (cooking), CHP engine for electricity and heat, grid injection capability

Pretreatment System
Includes substrate mixing, pre-treatment tank for homogenization

Regulatory Compliance
Meets governmental standards for grid-injection and organic fertilizer output

Expected Plant Life
25+ years with regular maintenance

Gas Yield
0.4-0.6 m3/kg VS added, depending on substrate

Biogas Collection Dome
High-yield collection system integrated within the digester for optimal gas management

Heat Recovery
Optional heat exchangers available for maximizing process energy usage

Data Logging
Integrated data acquisition for process monitoring

Environmental Compliance
Meets green energy guidelines and emission norms

Resilience
Performs well with daily feeding variations

Operation & Maintenance
Remote monitoring support; low manual intervention

Safety Device
Includes pressure relief valve, water trap, and gas monitoring sensors

Start-Up Time
30-45 days (biological stabilization phase)

Substrates Handling
Co-digestion of mixed organic waste (primary: food waste, secondary: animal manure, optional: crop residue)

Digestate Handling
Separate liquid and solid digestate; outputs directly usable as agricultural fertilizer or compost

Operation Mode
Continuous and batch feeding modes supported

Operational Grid Injection Agricultural Residue Dry Digestion Co-Digestion Anaerobic Digester Plant Trade Information

Minimum Order Quantity
1 Number

Delivery Time
4

About Operational Grid Injection Agricultural Residue Dry Digestion Co-Digestion Anaerobic Digester Plant

This fully operational biogas facility utilizes anaerobic digestion technology to process agricultural residues using a dry digestion method. By employing co-digestion, the plant blends diverse organic feedstockssuch as crop residues and animal manureto optimize digestion efficiency and maximize biogas yield. The facility is equipped with advanced upgrading systems that refine the raw biogas into high-purity biomethane. This biomethane is directly injected into the local gas grid, providing a reliable and continuous source of renewable energy to the community while displacing fossil fuels.

In addition to producing clean energy, the plant plays a crucial role in the circular economy by recycling agricultural waste. The organic byproduct of the digestion process, digestate, is captured and processed into nutrient-rich biofertilizer, returning valuable nutrients back to local farmland. This operation effectively reduces greenhouse gas emissions, supports sustainable farming, and enhances regional energy security.

High-Performance Biogas Production

This anaerobic digester plant utilizes a robust fixed dome design with reinforced concrete and steel, enabling efficient dry digestion and co-digestion of mixed organic substrates. It excels in gas yield, delivering up to 25,000 m3 of biogas monthly under optimal conditions, making it a reliable choice for agricultural, municipal, or industrial applications seeking green energy conversion and waste reduction.

Versatile Substrate Handling & Pretreatment

Our system manages diverse feedstocks-from food scraps to livestock manure and crop residues-using dedicated mixing and pre-treatment tanks for optimized homogenization. This flexibility allows continuous adjustment of inputs and maximizes biogas generation efficiency, ensuring ongoing productivity and adaptability to local resource availability.

Automated Control & Safe Operation

The plant comes equipped with automated PLC-based controls, integrated data logging, safety features like pressure relief valves, water traps, and gas monitoring sensors. This ensures operational safety, regulatory compliance, low labor needs, and provides remote monitoring capabilities for minimal on-site supervision.

Sustainable Energy & Agricultural Benefits

Beyond biogas, the plant's dual digestate outputs (liquid and solid) are ready for immediate agricultural use as eco-friendly fertilizers or compost. The grid injection readiness and combined heat and power (CHP) options enable comprehensive energy recovery and supply, benefiting both farm operations and local communities seeking sustainable energy solutions.

FAQ's of Operational Grid Injection Agricultural Residue Dry Digestion Co-Digestion Anaerobic Digester Plant:

Q: How does the digester plant manage different types of organic waste?

A: The plant is engineered for co-digestion, efficiently processing a mix of primary (food waste), secondary (animal manure), and optional (crop residue) substrates. Feedstocks are homogenized in a pre-treatment tank to optimize the digestion process and biogas yield, making the system adaptable to available organic resources.

Q: What are the main uses of the biogas produced by this plant?

A: Biogas can be directly used for cooking in gas stoves, supplied to CHP engines for combined heat and power generation (electricity and heat), or injected into the local natural gas grid thanks to the plant's grid-injection capability, providing multiple energy utilization options.

Q: When does the plant reach optimal biogas production after installation?

A: Following installation and commissioning, the plant enters a start-up and biological stabilization period of 30-45 days. After this phase, the system achieves a stable state for optimal and continuous biogas generation.

Q: Where can this anaerobic digester plant be installed?

A: The plant is custom-built to fit the specific site requirements, including dimensions and capacity (from 5 to 500 m3/day). It is suited for on-farm, municipal, or industrial settings with suitable biomass supply and available space for on-site installation and operation.

Q: What is the process flow for substrate handling and digestate management?

A: Input feedstocks undergo substrate mixing and homogenization in pretreatment tanks, followed by dry anaerobic digestion in the main reactor. After digestion, the plant separates digestate into liquid and solid fractions, each suitable for direct use as agricultural fertilizer or compost, promoting circular economy benefits.

Q: How is safety maintained during biogas production and usage?

A: The plant integrates pressure relief valves, water traps, and gas monitoring sensors to ensure safe operation. Automated PLC controls and data logging support remote monitoring and minimize manual intervention, enabling rapid response to any irregularities.

Q: What are the key benefits of this operational grid-injection biogas plant?

A: Key advantages include high biogas yields, robust substrate flexibility, reduced waste disposal needs, on-site fertilizer production, reliable energy output (for heat, power, or grid supply), low manual labor through automation, and environmentally compliant operation, supporting long-term sustainability.

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